Professional Documents
Culture Documents
December, 2017
STANDARD TECHNICAL SPECIFICATION FOR
RETROFIT OF WET LIMESTONE BASED
FLUE GAS DESULPHURISATION (FGD) SYSTEM
IN A TYPICAL 2 x 500 MW THERMAL POWER PLANT
December, 2017
P. D. Siwal,
Member (Thermal)
Central Electricity Authority
FOREWORD
Ministry of Environment, Forest and Climate Change (MoEF & CC) vide Notification
dated 7.12.2015 has brought out new emission norms for thermal power stations. To
meet the new emission norms, installation of flue gas desulphurization (FGD) system
has become essential in new as well as existing thermal power plants. There has been
a demand from stake holders that CEA, as an apex body in the power sector, should
bring out a standard technical specification of FGD system which can be used as a
guiding document by the utilities for installation of FGD system in their power plants
with reduced time for pre-award activities, design & engineering and equipment
manufacturing.
In line with above objective, CEA constituted a committee under Chief Engineer (TE&TD)
in July, 2017 with participation from major utilities and manufacturers for developing standard
technical specifications for wet limestone based FGD system as majority of thermal power
plants in the country are expected to be provided with wet limestone based FGD
system.
I am glad that CEA has finalized the document titled, “Standard Technical Specification for
Retrofit of Wet Limestone Based FGD System in a Typical 2 x 500 MW Coal Based Thermal
Power Plant” with valuable inputs from the committee members. This document can be used
for installation of FGD system in a new thermal power plant also. The document reflects pooled
experience and knowledge of participating engineers from CEA, utilities and FGD system
manufacturers. I hope that the utilities would find the document quite useful for retrofit/
implementation of FGD system in thermal power plants in an expeditious manner
towards compliance of MoEF & CC notification on new emission norms.
I wish to express my appreciation to all the members of the Committee viz. CEA, NTPC,
BHEL, UPRVUNL, TANGEDCO, Toshiba, L&T and Alstom (GE) for sharing their
experience and making valuable contribution in bringing out this document.
New Delhi
December, 2017 (P. D. SIWAL)
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
MAIN CONTENTS
General
Section- 2
System Description and Scope
Section- 3
Technical Specification - Mechanical Works
Section- 4
Technical Specification - Electrical Works
Section- 5
Technical Specification- Control &
Section- 6 Instrumentation Works
DETAILED CONTENTS
i
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
ii
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
iii
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
iv
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
v
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
vi
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
vii
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
viii
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
ix
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 1 (General Note, Applicability and Project Specific Information)
SECTION 1.0
1
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 1 (General Note, Applicability and Project Specific Information)
The compliance of emission norms of 100 mg/Nm 3& 200 mg/Nm3, the
required SO2 removal efficiency of FGD system to be installed shall be
in the range 90- 95%. For compliance of emission norms of 600 mg/Nm3,
the required SO2 removal efficiency of FGD system needs to be in the
range 60- 70%. The partial bypass of raw flue gas helps in increasing
the temperature of the mixed flue gas and increases the buoyancy of exit
flue gas leading to its wider dispersion. It also reduces the problem of
moisture condensation in chimney. In this specification, partial bypass of
raw flue gas has not been envisaged considering complexity of damper
control scheme and operational issues involved. Instead, 100%
treatment of the flue gas has been considered with required level of SO2
emission in treated gas to be achieved by the FGD supplier as per his
optimization for height of the absorber, limestone slurry feed etc.
The use of gas to gas heat exchanger (GGH) in FGD system has got
both merits and demerits. The GGH has advantage of reducing the
temperature of inlet raw flue gas to the absorber which reduces potential
of damage to scrubber internals in case of flue gas excursion and mal-
operation etc. Reheating of treated flue gas helps in preventing stack
condensation and also increases the buoyancy of flue gas exiting from
the chimney resulting in dispersion of pollutants over a wider area and
consequently reduced ground level concentration of pollutants.
However, GGH requires additional space, results in additional pressure
drop, leakage issues apart from adding to the cost. Even with GGH,
chimney flue(s) may require additional protection by way of lining or
resistive painting. The standard specification has been drawn without
GGH.
2
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 1 (General Note, Applicability and Project Specific Information)
However, in case the purchaser intends to provide for GGH in the FGD
system as per his own assessment, the standard specification shall need
to be modified for incorporation of relevant changes as required to this
effect.
a) The thermal power plant provided with FGD requires a wet chimney
of height smaller than that envisaged prior to MoEF&CC’s December
2015 notification. However, the chimney required is to be of wet type
with acid resistant lining for the flue(s). The retrofit of FGD in an
existing plant would require the existing chimney flue(s) to be
provided with acid resistant lining which requires a plant shutdown
period of about 5- 6 months. Considering the aspect of huge
generation loss associated with this and also huge cost of lining,
construction of a new chimney of adequate height, which can be
constructed in parallel to FGD, has been considered in this
specification. With this, plant shutdown of only about one month or
so shall be required for interconnection with FGD system, thus
avoiding on huge generation loss.
b) For a thermal power plant fitted with FGD, the required height of the
chimney is governed by quantum of SO2 being emitted from the
chimney. Vide draft notification dated 16.10.2017, MoEF&CC has
specified stack height for thermal power plants with FGD installation
for public comments. The stack height required to be provided is
indicated as below:
3
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 1 (General Note, Applicability and Project Specific Information)
1 2
vi) The provision for complete bypass of FGD system with use of isolation
dampers for power plant to operate through existing chimney during unit
start-up with oil firing or during any exigency has been considered in this
specification.
vii) The installation of wet limestone FGD system will require space near
existing chimney for scrubbers, limestone recirculation pumps, oxidation
air blowers, instrument air compressor and new wet chimney, space in
plant area for receiving & storage of limestone, space for limestone slurry
preparation, and space for gypsum dewatering, handling, storage. The
4
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 1 (General Note, Applicability and Project Specific Information)
layout of the FGD system for retrofit in the existing plant shall have to be
developed and optimized by the bidder as per pockets of areas available
at site and in consultation with the purchaser including for relocation of
some plant facilities, if required.
viii) Various inputs will need to be provided by the purchaser to the contractor
for installation of FGD and its interconnection/ integration with the
existing power plant. These will vary from plant to plant on case to case
basis. The purchaser shall make proper assessment of these
requirements and appropriately incorporate in the specification.
ix) The FGD system and new wet chimney shall be constructed within the
scheduled time without affecting operation of the existing plant/ units.
The plant shutdown will be taken only for interconnection of the FGD
system as per quoted/ mutually agreed period for the same in the
contract. The bidder shall properly plan and ensure that the work of
structural/ mechanical/ electrical/ C&I interconnection with the existing
plant systems is completed within the scheduled shutdown period. In
case time taken is more, liquidated damages shall be applicable for each
day of delay as indicated elsewhere in the specification.
The basic FGD scheme is as per limestone supply of size (-) 250 mm to
the plant. In case crushed limestone of size (-) 25 mm is supplied, the
limestone crushers shall not be required to be provided and limestone
conveyors after pent house shall be directly led to limestone bulk storage
silos. Further, the specification indicates the purity of gypsum to be
produced from dewatering system as minimum 90% subject to purity of
available limestone. The aspect of limestone supply, its composition
including purity needs to be firmed up by the purchaser and incorporated
in the standard specification.
5
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 1 (General Note, Applicability and Project Specific Information)
The clause 4.3.1 (vii) specifies the absorber tower, oxidation tank,
absorber internals & other parts, absorber outlet duct to be provided with
minimum 2 mm thick lining/ cladding of SS 317 LMN / Alloy 31/ Hastelloy
C22/ C 59/ C276 or equivalent. The purchaser, as per his own
assessment and considerations, may decide to go in for other applicable
materials also such as rubber lining (minimum 4 mm thick), flake glass
lining (minimum 3 mm thick). In such case, necessary changes shall
need to be incorporated in the relevant sections of the standard
specification.
6
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 1 (General Note, Applicability and Project Specific Information)
provided for the FGD system. This needs to be checked and firmed up
by the purchaser and incorporated in the relevant part of the standard
specification.
1.2 APPLICABILITY
This standard technical specification for retrofit of FGD system has been
prepared considering a thermal power plant comprising of 2x500 MW units
installed prior to 1st January, 2017 for which notified SO2 emission limit is 200
mg/Nm3. The document covers only technical part of the specification in a
comprehensive manner as described herewith in nine (9) sections. The
specification can be made applicable for other power plants also having
different size & number of units and different notified SO 2 emission limit
making suitable corrections for indicated technical parameters and other
aspects as felt necessary by the purchaser.
1.3 BRIEF DETAILS ABOUT POWER PLANT
i) Site Data
2 Owner ---
7
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 1 (General Note, Applicability and Project Specific Information)
ii) Coal
M/s --- has received firm linkage of --- million tonnes of coal per annum
from ----mines of --- coalfields of M/s ---.
iii) Water
The ---thermal power plant has allocation of --- m3/h of water from -----
river/canal/reservoir of ---state for meeting the fresh water requirement
of plant.
i) Plant data
a) Boiler
Make : BHEL,
Type : Pulverised coal fired,
Balanced draft, Dry bottom
BMCR : 1590 t/hr,
Steam pressure at SH outlet : 179 kg/cm2
Steam temperature at SH outlet: 5400C
Steam temperature at RH outlet: 5680C
b) Steam Turbine
Make : BHEL, KWU Design
TMCR : 500 MW
Max. load under VWO : 525 MW
To be provided by purchaser
To be provided by purchaser
8
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 1 (General Note, Applicability and Project Specific Information)
c) Electrostatic Precipitator
Make : BHEL
Efficiency : 99.91 %
No. of gas paths/boiler : 4
No. of fields/gas pass : 8
Outlet SPM emission : < 100 mg/Nm3
ii) Fuel
a) Coal Analysis
b) Heavy Fuel Oil (HFO) Specification- used for startup/low load only
c) Light Diesel Oil (LDO) Specification- used for startup/low load only
Standard IS 1460/1974 Grade LDO
Flash point minimum (Pensky 66oC
Martens closed cup)
Viscosity maximum 15.7 CST at 38oC
Total sulphur maximum 1.8 % by weight
Gross heating value 10300kcal/kg.
9
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 1 (General Note, Applicability and Project Specific Information)
iii) Water
The raw, cooling, cooling and DM water analysis are given at Annexure-
I to IV respectively of the specification.
iv) Limestone
Lime stone is being procured from …mines of size…... and shall be
brought to plant by trucks. The analysis is given at Annexure-V of the
specification.
*******
10
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
SECTION 2.0
GENERAL
2.1.2 Scope of the proposal shall cover following activities and services in respect of
all the equipment and works specified in various sections of this specification:
i) Basic Engineering of all equipment and equipment systems;
ii) Detailed design of all the equipment and equipment system(s) including
civil works;
vi) Packing and transportation from the manufacturer’s works to the site
including customs clearance, port charges, if any;
11
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
xii) Supply of any other equipment including special tools and tackles,
commissioning spares and services required for satisfactory completion
of the project and operation and maintenance of the same;
xvi) All items and equipment though not specifically mentioned in the
specification, but needed to complete the system to meet the intent of
the specification shall be deemed to be included in the scope of the
bidder.
2.1.4 It is not the intent to completely specify all details of design and construction,
but only to lay down broad sizing and quality criteria for the major equipment
and systems and it is expected that the equipment shall conform in all respects
to high standards of engineering, design and workmanship and shall be capable
of performing in continuous commercial operation up to the contractor’s
guarantee in a specified manner acceptable to the purchaser.
Dust laden flue gases from second pass of the boiler are divided into two paths
to enter 2x60% capacity rotary regenerative air pre-heaters wherein heat of
the flue gases is transferred to primary and secondary combustion air. Flue
12
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
The flue gas ducts are divided into two independent streams. However,
interconnection with isolating dampers are provided at the inlet and outlet of
major important equipment i.e. air pre-heaters, ESPs, ID Fans, to ensure
flexibility of operation with any one of the equipment being out of service. Each
of the equipment on flue gas path i.e. APH, ESP, ID fan is provided with
isolating dampers at its inlet and outlet for on line maintenance. The vendor
is expected to maintain similar uniformity in all aspects of the duct work in his
scope.
The twin flue chimney is of 275 m height in RCC construction. The flues inside
the RCC chimney are fabricated from structural steel conforming to Grade
E250 (Fe410W), quality A (semi killed) of IS:2062 from rolled steel members
and plates. Stainless steel used for the top portion of flue conforms to AISI
type 304L. Each flue is of hung type (i.e. of tension type) suspended from
support floors with expansion joints above support floor.
The rectangular cross section duct is connected to flue inside the chimney by
means of bolted flange connections. The duct is supported on steel frame
inside and outside the chimney shell. The duct is fabricated out of steel of
grade E250 (410W) quality (killed).
2.4.1 i) The FGD plant for each unit of 2x500 MW thermal power station shall be
designed to comply with the requirements/ conditions as indicated below:
13
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
ii) The flue gas analysis at FGD inlet (ID fan outlet) shall be considered as
below:
2.4.2 Bidder shall also guarantee that maximum concentration of SO2 in treated flue
gas at the exit of FGD for each unit shall not exceed 150 mg/Nm3 (6% O2, dry
basis) under all operating conditions of the plant in the load range 50% TMCR
to 100% TMCR.
ii) The complete FGD system and the associated auxiliaries shall be
designed by the standard industrial practices. The FGD system shall be
designed to achieve the required SO2 capture without the use of oxalic
acid or any other additives.
iii) Justification of Proposed Design- The Contractor shall also furnish along
with his offer the detailed calculations and data to establish as to how he
will meet the performance requirements at specified guarantee point.
14
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
iv) The Bidder shall submit with the offer, comprehensive information on
how the L/G ratio, mass balance, spray nozzle cone angle, spray nozzle
arrangement, limestone consumption etc. as applicable for the proposed
design have been arrived at. The Contractor shall also submit along with
the offer, a detailed write up on the proposed design features and control
philosophy at varying loads to achieve the desired level/ efficiency of SO 2
removal.
v) The FGD plant shall be designed for a service life of minimum twenty five
(25) years.
vi) Adequate margins shall be considered in design capacity and head of
the pumps and fans over and above the maximum duty conditions in
addition to increase in frictional losses over a period of 25 years and 5%
fall in the frequency of electric supply.
vii) Stable capacity/head rising characteristics shall be provided for the
pumps and the shut off head shall be minimum 20%over the rated head.
viii) All pressure vessels shall conform to requirements of IS 2825or ASME
Section VIII. The minimum thickness of pressure vessels shall, however,
be 6 mm.
ix) The design pressure of pressure vessels shall be equal to the algebraic
sum of the maximum total head encountered in H.Q. characteristic of the
preceding pump stage and the total suction head of the same pump plus
5% margin.
x) For unlined pressure vessels 2-mm corrosion allowance is to be made.
Also 2-mm mill tolerance shall be made for all dished ends.
xi) For tanks coming in contact with corrosive fluids, no corrosion allowance
is required but should be rubber lined at least 5mm thick or flake glass
lined with minimum 3 mm thickness as per proven experience of the
supplier, unless otherwise specified elsewhere. Rubber lining of vessels
shall be as per IS: 4682 (Part I).
xii) All steel pipelines unless otherwise specified elsewhere carrying
corrosive fluids should be rubber lined inside to a thickness of at least 5
mm. FRP material may be considered for smaller diameter pipes where
lining is not feasible.
xiii) All pumps shall have discharge pressure gauges (with isolating valves)
suitable to handle the particular fluid for which they are intended for.
xiv) All centrifugal pumps shall have suction and discharge gate/ butterfly
valves, and check valves on the discharge side unless otherwise stated.
xv) All tanks and sumps handling slurry shall be provided with adequate
number of agitators.
xvi) Sampling connections, as required, shall be provided at different stages
of the FGD plant.
xvii) All valves which a normal person cannot operate standing on the floor
should be provided with chain operation.
15
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
xviii) The water velocities in pressure lines shall not exceed 2.4 m/sec. and
pump suction line velocities shall not exceed 1.0 m/sec. except otherwise
specified elsewhere in this specification.
xix) The maximum temperature of ambient air for the purpose of designing
the capacities of fans and motors shall be taken as 50degC.
xx) All metallic valves coming in contact with corrosive fluids shall be rubber
lined metallic valves or of proven material suitable for the duty involved.
xxi) The contractor shall supply all essential instrumentation and other
accessories required for satisfactory and reliable performance of the
FGD plant.
xxii) Wherever motors are specified to be TEFC weather proof or TEFC
weather protected, it shall mean that they will be TEFC suitable for
outdoor installations. All motors shall comply with specific technical
requirements given in this specification.
xxiii) All instruments shall be provided with isolating globe/needle valves (foot
valves) of suitable material.
xxiv) Wherever applicable, all level gauges, shall be provided with isolating
and drain valves.
xxv) The size of overflow pipes of all storage tanks shall be one size higher
than inlet pipe sizes of these tanks.
xxvi) For buried pipelines, three (3) coats of heavy duty bituminastic paint shall
be applied on the cleaned surface. Finally, it shall be wrapped with
minimum 3 mm thick bitumen impregnated tar-felt. The lap joint of the
felt should be touched with paint.
xxvii) Heavy duty hume pipes of adequate size shall be provided for road
crossing etc. of the buried pipe lines.
xxviii) Pipelines at interface terminal points shall be provided with blank flange
arrangement, unless otherwise specified.
xxix) Recirculation lines shall be provided for each centrifugal pump, unless
otherwise specified.
xxx) Each equipment/motor shall be earthed with two Nos. distinct and
independent earthing electrodes.
xxxi) Construction Material and Internal anticorrosive Protection:
a) In general, the material selection is the Bidder’s responsibility, but the
quality of material for pressure vessels, piping, etc., however, must
meet the requirements of the relevant IS/ASME standards. The Bidder
shall specify in his bid the material quality and the standards applied
to each equipment, piping system, etc.
b) Suitable corrosion and erosion allowances shall be provided
commensurate with service conditions of the equipment. The
corrosion allowances shall be determined by the Bidder on the basis
of his experience/standard practice. Corrosion allowances
considered for various equipment and piping system etc. shall be
indicated in the bid. Similar data shall be given for erosion allowances.
16
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
i) The FGD plant for each unit shall be designed to achieve minimum 92%
(to be provided by Purchaser) SO2 removal efficiency at all operating
conditions from 50% to 100% of Unit MCR.
ii) The FGD plant shall be capable of base load operation at minimum 95%
availability. The bidder shall also furnish details of availability records in
plants stated in his experience list.
iii) System shall be capable of safe shut down in case of unit tripping and/or
station black out. Customer shall try to provide emergency AC supply
for FGD system from station emergency AC supply. However, if in case
it is not feasible to do so, bidder may be required to include emergency
AC supply for FGD equipment needing such supply in case of unit
tripping /station black out in his scope and shall have to provide DG sets
of adequate capacity. Bidder may indicate price for providing
emergency AC supply separately in the price bid.
iv) The normal flue gas temperature at inlet to FGD shall be about 120-
1350C. However, in case of APH failure the flue gas temperature may
rise to about 2500C for 15 minutes and the FGD system shall be
designed to suitably withstand such operation without any damage to the
system. All duct work/duct lining, dampers etc. shall be designed to
withstand above temperature conditions.
v) The provision shall be made for complete bypass of FGD system during
unit start-up with oil firing (LDO)/ HFO) or during any plant operational
exigency with use of isolation dampers to enable power plant operation
through existing chimney.
17
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
vii) The FGD plant shall be suited to an unlimited operation at any load point
between the minimum and maximum load point being guaranteed. The
plant shall be capable of being put into service (both warm and cold start-
up) without the necessity of extensive and unusual activities or
preparations.
viii) The FGD plant shall be able to handle the load imposed on the FGD
plant by the boiler, including rate of load changes, minimum load and
the anticipated daily and annual load schedules. Furthermore, the FGD
plant shall be able to be put in operation, while the boiler is in operation
at any load, without any disturbance in the operation of the Units.
xiv) The operation and supervision of the FGD plants and the ancillary
facilities shall be carried out fully automatically by its own dedicated PLC
system. When necessary, it shall be possible for the control room staff
to intervene and control the plant. Start-up and shut-down procedures
shall be possible by means of semi-automatic operations which shall be
released and supervised by the control room.
xv) In case of a failure of an item of equipment (e.g. pumps, etc.) the stand-
by unit has to be activated and put into service automatically without
delay and without interruption of the plant operation and audio-visual
alarm to such effect shall be provided in the control room.
xvi) In case of a power failure, all items of equipment which could possibly
suffer irreversible damage shall be connected to the emergency power
supply.
xvii) In case of failure of the boiler and ancillary equipment, the associated
FGD plant shall be brought automatically to the off-load operation without
restriction by the current loading.
xviii) In case of shutdown and outage periods of the plant, drains and flushings
of respective items of equipment which require such a treatment e.g.
lime slurry preparation and supply, pipes, binds, etc. shall be possible
without restriction and without necessity of extensive or unusual
preparation and activity. Drains and flushings required even during short
time outages or an emergency shut-down shall be started automatically
and by remote control. This requirement shall be applicable to limestone
slurry and gypsum slurry pipe work and all other items being in contact
with lime stone or gypsum slurry in any case. Acid flushing equipment
shall also be provided if necessary for flushing these items of equipment.
The system shall be complete with storage tank, pumps, pipe work,
fittings, etc. The system shall work automatically, locally activated by a
local control unit.
18
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
The Contractor shall offer the optimum design and layout to accommodate the
flue gas system, absorber system, limestone handling & storage system and
gypsum handling & storage system and a new wet flue chimney within the
confines of the space available.
The absorber and its auxiliaries and wet stack shall preferably be located
around/ near the existing chimney. Bulk limestone storage (covered shed)
shall be provided at a suitable location within the plant boundary from where
limestone shall be transported to limestone crushing area by dumper/ trucks.
The limestone grinding, slurry preparation and storage system shall be
housed together. Gypsum dewatering, gypsum storage and effluent treatment
plant shall be housed in multi story building at a suitable location nearest to
the absorber. Gypsum storage area shall preferably be provided on ground
floor, below the vacuum belt filters, for easy Gypsum handling and
transportation.
iii) Platform with a minimum clear width of 1000 mm shall be provided all
around the lowest absorber spray levels and mist eliminators. Similar
platforms shall be provided at subsequent elevations if they are more
than 3000 mm apart from each other. An adequately sized manhole with
platform shall be provided above each spray level. Ladders/staircase
shall be provided for the access to the platform.
iv) The absorber slurry recirculation pumps (for spray tower systems),
gypsum bleed pumps and limestone feed pumps shall be mounted on
the ground level. Suitable approach and platforms shall be provided for
all the valves required during regular operation.
19
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
vi) Platform with a minimum width of 1200 mm shall be provided all around
the mills and feeders. Approach along with suitable platforms shall be
provided for ball loading hoppers.
viii) A 2000 mm wide floor/platform shall be provided all around each belt
filter.
ix) The Contractor shall provide adequate handling facility with motorized
hoist, runway beams etc. for handling/ maintenance of heavy
components. Motorized hoists shall be provided for handling all
components exceeding 500 kg.
x) The regular basement and local pits/trenches etc. shall be avoided as far
as possible.
xiii) All other safety requirements as per the CEA Regulation, Factories Act,
Indian Electricity Rules and other applicable codes/standards etc. shall
be complied with while developing Layout.
xv) Each Equipment room shall be provided with alternate exits in case of
fire/ accidents as per requirements of Factories Act and Statutory bodies/
insurance companies.
xvi) Minimum Headroom (free height) under all floors, ducts, walkways and
stairs shall be 2 m.
xviii) In case of any specific space constraint at site, the layout, clearance,
approach etc. shall be mutually agreed and subject to approval of the
purchaser.
20
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
2.8.1 All equipment, systems and works covered under these specifications shall be
in accordance with all the latest applicable statutes, regulations, codes and
standards specified as well as all such standards, statutes, regulations and
safety codes applicable in the locality where the equipment will be installed.
Bidders may familiarize themselves with all such requirements before
preparation of bids. FGD plant design including piping, valves and fittings
shall completely meet or exceed all the requirements of the latest versions of
Indian Standards/ASME codes. In all other cases where IS/ASME does not
govern, Japanese, American, British, German or other international standards
established to be equivalent or superior to IS/ASME shall be acceptable with
the approval of the purchaser at the time of detailed engineering. In the event
of any conflict between the requirements of equivalent codes and standards,
and the requirements of IS/ASME code, the latter shall govern unless
specified elsewhere in the specifications.
2.8.2 The responsibility of safe, efficient and reliable operation of the equipment and
system supplied shall rest on the supplier and the approval of the
drawings/documents shall not in any way relieve the manufacturer of this and
obligation to meet all the requirements stipulated in the specification or of the
responsibility for correctness of the drawings/documents.
2.8.4 The wet limestone FGD system offered by the bidder shall be in line with the
specified scheme of FGD process. However, minor variations are permissible
for optimization of the process based on bidder’s experience. These
variations shall, however, not change the basic essence or configuration of
the process specified. Specific advantages of such variations shall be
indicated by the bidder in his bid. All modifications/variations proposed from
the process specified shall be subject to approval from the purchaser.
Description of the process which has been offered by the Bidder must be
submitted in detail indicating clearly the function of each equipment.
2.8.5 The materials of construction for all exposed metal/ concrete surfaces shall be
so chosen as to withstand the prevailing environment at plant site. Also
suitable weather protection shall be provided to all exposed surfaces as
required. The equipment and the auxiliaries shall be designed for maximum
reliability and availability; operability and maintainability. The bidder shall
specifically state the design features incorporated to achieve the high degree
of reliability and availability.
21
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
2.8.7 Complete thermal, mechanical and electrical functions of the station are to be
remotely controlled from the unit control desk/ Panel (located in common
control room) during normal as well as emergency operating conditions.
2.8.8 Wherever oil coolers of any equipment are provided, these shall be of 3x50%
or 2x100% capacity to facilitate cleaning without shutting down the equipment.
All coolers/jackets shall be designed to take care of the operating pressure of
the cooling medium.
2.8.9 All stand-by auxiliaries shall be designed for auto start up, on failure of running
auxiliaries with minimum time delay and without runback on unit load.
2.8.10 The bidder shall endeavor to supply the equipment (motors, valves, actuators,
instruments etc.) of same type and make to the extent possible so as to reduce
the spare parts inventory. However, this must not affect the functioning and
operational reliability of the given equipment.
2.8.11 All the electric motor driven equipment shall give their rated performance even
at a power supply frequency of 47.5 Hz (minimum). All equipment and
auxiliaries shall be suitable for continuous operation in the frequency range of
47.5 Hz to 51.5 Hz.
2.8.12 The plant and its units shall be designed to operate with all the specified
margins for continuous operation without any limitations under any of the
conditions indicated in the Technical Specification.
2.8.13 All materials used for the construction of the equipment shall be new and shall
be in accordance with the requirements of this specification. Materials utilised
for various components shall be those which have established themselves for
use in such applications. It would be the responsibility of the bidder to furnish
the relevant information in this regard, as required, at the time of detailed
engineering,
22
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
2.8.15 Roller bearings provided on pumps, fans, air compressors, GGH, agitators
and other equipment shall have a life of at least 10 years with maximum
loading conditions. Journal bearings provided should have operational life
equal to the life of the equipment
2.8.16 The bidder shall develop detailed layout drawings with his equipment sizes
and confirm the adequacy of the space available for housing FGD equipment.
Layout should facilitate access for operation, maintenance and inspection of
any one or more equipment/components at a time, without disturbing the
operation or installation of balance of plant. The offers not fitting into the space
allocated for the purpose are liable to be rejected.
2.8.17 All heavy parts of the plant must be provided with some convenient
arrangement for aligning and for handling during erection and overhaul. Any
item of plant required to be stripped or lifted during period of maintenance and
weighing one tons or more shall be marked with its approximate weight. All
equipment shall be designed to run satisfactorily without any undue noise and
vibrations. Corresponding parts throughout shall be made to gauge and shall
be interchangeable wherever possible. No welding, filling or plugging of
defective parts shall be allowed without the permission in writing of the
purchaser.
2.8.18 Each main and auxiliary item of plant shall have permanently attached to it in
a conspicuous position, a rating plate of non-corrosive material upon which
shall be engraved manufacturer’s name, equipment, type or serial number
together with details of the ratings, service conditions under which the item of
plant in question has been designed to operate, and such diagram plates as
may be required by the Engineer. The inscriptions on the name plates as also
the material and design of the name plates shall be approved by the Engineer.
2.8.19 The contractor shall intimate the purchaser in writing of any changes proposed
in design, manufacturing methods or materials from those included or implied
in his tender giving reasons, for purchaser’s approval. The changes shall be
23
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
allowed only after written approval of the purchaser. The purchaser recognizes
the importance of including the latest principles and design information in the
final design of any plant.
i) All valves shall be suitable for the service conditions i.e. fluid flow,
temperature and pressure under which they are required to operate and
those performing similar duties shall be interchangeable with one
another unless otherwise approved.
ii) All gate valves shall be of the full way type unless otherwise approved
and when in the full open position, the bore of the valve shall not be
obstructed by any part of the gate. Globe valves shall have curved or
spherical seating and the discs shall be free to revolve on the spindle.
iii) All non-return valves shall have an arrow cast or embossed on the side
of the valve body to indicate the direction of flow. For severe service
conditions, cushioned check valves are preferred to obviate valve clatter.
In case of the swing check valves, the body seat shall be inclined at such
an angle to the vertical so as to facilitate closing and prevent clatter.
iv) The internal diameter of all valve ends to be connected to pipes shall be
the same as the internal diameter of the pipe to which they are joined so
as to minimize use of reducers/expanders.
v) Where applicable valves shall be of the outside screw and yoke type.
24
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
viii) All sampling and root valves furnished shall be of integral body bonnet
type.
ix) Where necessary for the safe and efficient operation of the plant, valves
shall be provided with both hand and actuator operating gear. The
valves shall be complete in all respects including actuator and necessary
limit switches, torque limit switch linkages etc.
x) Each motorized valve shall be supplied with two sets of position operated
adjustable limit switches each for open and close positions for signaling
and interlocking. In addition, two numbers torque limit switches (one for
fully open position and the other for fully closed position) shall be
provided.
xi) In case of regulating valves, provision shall also be made for suitable two
numbers resistance position transmitters for remote position indication.
xii) All gate and globe valves shall have bonnet-back seating arrangement
to facilitate easy replacement of packing with the valves in service.
xiii) All gate, globe and check valves shall be designed for reconditioning of
seating surfaces and replacement of stem and disc without removing the
valve body from the line.
xiv) Wherever there is a provision for local control of valves, position indicator
shall be readily visible from the operation position.
xv) All valves and specialties shall bear tag numbers for identification.
xvi) The scheme/arrangement of valves and fittings shall be such that it shall
be possible to do the maintenance of the control/regulating valves and
spare/standby equipment without shutting down the FGD plant. All the
control valves in the system shall be of 2x100 % capacity with proper
isolating valves upstream and downstream of control valve for
maintenance. The valves located in the inaccessible positions shall be
motorized even if not required functionally.
xvii) Necessary drain lines with valves of adequate size for draining the
system and to achieve low pressure loss and low noise level shall be
provided. All the drain lines shall be led to the nearest waste water
treatment plant. The air release valves shall be fitted with an inverted ‘U’
pipe on the outlet and drain piping to the nearest drain. All drain and air
release valves shall be located in positions convenient for operation. No
drain line shall be sized below 25 mm ID. All drain lines shall be provided
with two isolating globe valves in series.
25
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
2.8.23 Hangers, anchors, guides, clamps, stops and supports, auxiliary structures
etc. Required for the proper installation supports of the piping shall be
provided.
2.8.24 The isolators and dampers provided in the gas ducts shall be 100% leak proof
(zero leakage type) so as to completely isolate and permit the maintenance of
FGD plant and accessories, with the unit in operation with FGD bypassed
2.8.25 Noise level should not be more than 85 dB at a distance of 1 meter and at a
height of 1.5 meter from any equipment except for limestone crushers and
limestone wet ball mills for which noise level shall not exceed 90 dB each. If
necessary, suitable noise reduction covers shall be provided. For short term
exposure, noise levels shall not exceed the limits as stipulated in the
Occupational Safety & Health Administration Standard (OSHAS). Compliance
to noise level shall be demonstrated by the bidder.
2.8.26 All the electric motor driven auxiliaries shall be sized to give their rated
performance even at a power supply frequency of 47.5 Hz. (minimum).
2.8.27 Lubrication
Provision shall be made for lubricating the parts wherever necessary to ensure
smooth operation and freedom from undue wear. Gear boxes and oil bath
shall be provided with filling and drain plugs of adequate size and shall be
provided with level indicators. Provision shall be made for efficient lubrication
of all bearings including ball and roller bearings by the use of separate grease
cups, self-sealing nipples or oil bath. Housing of ball and roller bearing shall
be packed with the lubricant at the time of assembly. Lubrication opening of
nipples shall be so arranged that it should be possible to carryout lubrication
from a gangway or landing and without the removal of or insertion of the hand
into the guarding. Necessary provision shall be made for preventing dust
ingress into lubricated parts. The contractor shall supply schedule drawing
showing all lubricating points and recommended lubricants to be used. First
fill of the lubricants wherever required and all lubricants till handing over of
FGD system, shall be supplied by the contractor.
26
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
27
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
ii) The tools shall be supplied in separate containers clearly marked with
the name of equipment for which they are marked.
iii) The bidder shall furnish a list of such tools included under the scope of
supply with the proposal.
2.8.33 All manholes and inspection openings shall be hinged and shall be suitable
for easy opening/closing. All inspection openings and manholes shall be
provided with maintenance platforms for easy access. Dust catchers shall be
provided in order to prevent discharge of dust when opening the doors and
manholes.
2.8.34 Every equipment or parts of equipment that must operate under certain
conditions of maximum pressure, temperature, speed, position etc. should
have devices to prevent such limits from being exceeded and, if necessary, to
stop the operation of the machine. (Safety valves, limit switches, thermal
switches, etc.).
28
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
ii) Items of plant such as valves, which are subject to handling, shall be
provided with engraved chromium plated nameplate or label with
engraving filled with epoxy. The name plates for valves shall be marked
in accordance with MSS standard SP-25 and ANSI B 16.34 as a
minimum.
i) All materials used in the manufacture of the equipment shall be free from
defects and imperfections. The purchaser will reject components and
equipment with bad workmanship and the supplier shall have to re-
supply equipment of right workmanship at no additional cost to the
purchaser.
iii) The materials used in the fabrication of the components shall be new and
shall have such composition, grade and properties which match and suit
the duties to be performed and the conditions of operation to which these
components will be subjected. Site-specific conditions shall be
especially taken care of in the choice of materials proposed to be
adopted.
29
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
The bidder shall include in his scope of supply all the necessary mandatory
spares, start up and commissioning spares and recommended spares and
indicate these in the relevant schedules. The requirements pertaining to the
supply of these spares is given below:
i) Mandatory Spares
30
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
d) The purchaser reserves the right to buy any or all the mandatory
spare parts.
31
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
all such start up and commissioning spares and keep an adequate stock
of the same to be brought by him to the site for the plant erection and
commissioning. These must be available at site before the equipment
are energized. The unused spares, if any, should be removed from there
only after commercial operation of the plant. All start up spares which
remain unused at the time shall remain the property of the Contractor.
a) The Contractor shall indicate the service expectancy period for the
spares parts (both mandatory and recommended) under normal
operating conditions before replacement is necessary.
g) The Contractor will provide the purchaser with all the addresses and
particulars of his sub-suppliers while placing the order on vendors for
items/ components/ equipment covered under Contract and will
further ensure with his vendors that the purchaser, if so desires, will
have the right to place order for spares directly on them on mutually
agreed terms based on offers of such vendors.
h) The Contractor shall warrant that all spares supplied will be new and
in accordance with the Contract documents and will be free from
defects in design, material and workmanship.
32
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
33
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
34
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
viii) All material used for equipment construction including castings and
forgings etc. shall be of tested quality as per relevant codes/standards.
Details of results of the test conducted to determine the mechanical
properties, chemical analysis and details of heat treatment procedures
recommended and actually followed shall be recorded on certificates and
time temperature chart. Tests shall be carried out as per applicable
material standards and/or agreed details.
ix) All welding and brazing shall be carried out as per welding procedure
drawn and qualified in accordance with requirements of ASME Section
IX/ BS-4870 or other International equivalent standard acceptable to the
Owner. Welding procedures shall be submitted to the Purchaser for
approval prior to carrying out Qualification test in the presence of
Purchaser’s representative.
xi) Test results of qualification tests and specimen testing shall be furnished
to the Purchaser for approval. However, wherever required by the
purchaser, tests shall be conducted in presence of Purchaser’s
Engineer/ authorized representative.
xii) Unless otherwise proven and specifically agreed with the Owner, welding
of dissimilar materials and high alloy materials shall be carried out at
shop only.
xiii) No welding shall be carried out on cast iron components for repair.
xiv) All the heat treatment results shall be recorded on time temperature
charts and verified with recommended regimes.
35
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
xvi) All plates of thickness above 40mm & all bar stock/Forging above 40mm
dia shall be ultrasonically tested. For pressure parts, plate of thickness
equal to or above 25mm shall be ultrasonically tested.
xviii) For all spares and replacement items, the quality requirements as
agreed for the main equipment supply shall be applicable.
xx) All the sub-vendors proposed by the Bidder for procurement of major
bought out items including castings, forgings, pumps, fans, heat
exchangers, semi-finished and finished components/equipment- (list of
which shall be drawn up by the Bidder along with his offer and finalized
with the purchaser) shall be subject to Purchaser’s approval.
xxi) All the purchase specifications for the major bought out items, list of
which shall be drawn up by the Contractor and finalized with the
purchaser, shall be furnished to the Purchaser for comments and
subsequent approval before orders are placed as per those
specifications.
xxii) Purchaser reserves the right to carry out quality audit and quality
surveillance of the systems and procedures of the Contractor and their
sub-vendors for quality management and control activities. The
Contractor shall provide all necessary assistance to enable the
purchaser carry out such audit and surveillance.
2.11.1 General
i) The Contractor shall undertake an inspection and testing programme
during manufacture in his works and that of his sub-contractors to ensure
the mechanical accuracy of components, compliance with drawings,
conformance to functional and performance requirements, identification
and acceptability of all materials, parts and equipment. In addition to
tests as per the approved Quality Plan, the Contractor shall also carry
out all tests/ inspection required to establish that the items/ equipment
conform to requirements of this specification and the relevant codes/
standards specified in this specification.
36
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
ii) The word ‘Inspector’ shall mean the Purchaser/ Engineer and/or his
authorized representative and/or an outside inspection agency acting on
behalf of the Owner to inspect and examine the materials and
workmanship of the works during its manufacture or erection.
iii) The Purchaser/ Engineer and/or his duly authorised representative shall
have at all reasonable times access to the contractor’s premises or works
and shall have the power at all reasonable times to inspect and examine
the materials and workmanship of the works during its manufacture or
erection and part of the work being manufactured or assembled on
other’s premises or works. The contractor shall obtain for the Engineer
and his duly authorised representative the permission to inspect as if the
works were manufactured or assembled on the contractor’s premises or
works.
iv) The contractor shall give the Engineer/Inspector fifteen (15) days written
notice of any material being ready for testing. Such tests shall be to the
contractor’s account except for the expenses of the Inspector. The
Engineer/Inspector unless the inspection of the tests is virtually waived,
shall attend such tests within fifteen (15) days of the date on which the
equipment is notified as being ready for test/inspection, failing which, the
contractor may proceed with the test which shall be deemed to have
been made in the Inspector’s presence and he shall forthwith forward to
the Inspector duly certified copies of tests in triplicate.
v) The Engineer or Inspector shall within fifteen (15) days from the date of
inspection as defined herein give notice in writing to the contractor of any
objection to any drawings or any equipment and workmanship which in
his opinion is not in accordance with the contract. The contractor shall
give due consideration to such objections and shall either make the
modifications that may be necessary to meet the said objections or shall
confirm in writing to the Engineer/Inspector, giving reasons therein that
no modifications are necessary to comply with the contract.
vi) When the factory tests have been completed at the contractor’s or sub-
contractor’s works, the Engineer/Inspector shall issue a certificate to this
effect within fifteen (15) days after completion of test. If the tests are not
witnessed by the Engineer/Inspector, the certificate shall be issued
within fifteen (15) days of the receipt of the contractor’s test certificate by
the Engineer/Inspector. Failure of the Engineer/Inspector to issue such
a certificate shall not prevent the contractor from proceeding with the
works. The completion of these tests or the issue of the certificate shall
not bind the owner to accept the equipment, should on further tests after
erection, the equipment is found not to comply with the contract.
vii) In all cases where the contract provides for tests whether at the
premises or works of the contractor or of any sub-contractor, the
contractor, except where otherwise specified, shall provide free of
charge such items as labour, materials, electricity, fuel, water, stores,
apparatus and instruments as may be reasonably demanded by the
Engineer/Inspector or his authorised representative, to accomplish
testing.
37
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
viii) Quality audit/ surveillance/ approval of the results of the tests and
inspection will not, however, prejudice the right of the purchaser to reject
the equipment if it does not comply with the specification when erected
or does not give complete satisfaction in service and the above shall in
no way limit the liabilities and responsibilities of the Contractor in
ensuring complete conformance of the materials/equipment supplied to
relevant specification, standards, data sheets, drawings etc.
ix) All inspection, measuring and test equipment used by Contractor shall
be calibrated periodically depending on its use and criticality of the
test/measurement to be done. The Contractor shall maintain all the
relevant records of periodic calibration and instrument identification, and
shall produce the same for inspection by the Purchaser/ Inspector.
Wherever asked specifically, the Contractor shall re-calibrate the
measuring/test equipment in the presence of Purchaser/ Inspector.
x) The cost of all the tests shall be borne by the Contractors.
Wherever tested quality material is specified and wherever called upon by the
design code, the test pieces are to be prepared and tested to the Purchaser’s
satisfaction. The Purchaser may, at his discretion, after being furnished with
certified particulars of tests which have been carried out by the suppliers of
material, dispense with the testing of test pieces.
i) Shop tests shall include all tests to be carried out at Contractor’s works,
at the works of his sub-contractor and at works where raw materials
supplied for manufacture of equipment is manufactured.
ii) Works tests are to include electrical and mechanical performance and
hydraulic tests in accordance with relevant IS, ASME or any other
approved standard and/or any other tests called for by the Purchaser
under these specifications to ensure that the plant being supplied fulfils
the requirement of the specifications. For equipment not covered by any
IS or other approved standards, the tests to be carried out shall be in
accordance with Contractor’s quality assurance programme to be agreed
to between the Contractor and the Purchaser.
iii) All pipes, valves, steam traps, are to be subjected to hydraulic test as
called for under IS, BS or other approved codes. Copies of certificates
covering all the hydraulic tests shall be submitted to the purchaser. The
following shop tests shall be conducted, as applicable according to the
approved manufacturer’s test Procedures:
a) Material Analysis
b) Radiographic test at welds.
c) Magnetic particle examination
38
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
iv) All pumps and fans are to be tested at manufacturer’s works. Complete
performance tests are to be carried out on each pump/ fan to verify its
output (flow) against total head, power input, efficiency and suction head.
Head vs. Volume, Suction head vs Volume, Volume vs Efficiency and
power input curves corrected for site conditions are to be provided.
Contractor shall carry out the tests at site to prove to the purchaser that each
equipment of the plant complies with all the requirements specified. Before the
plant is put into commercial operation, the Contractor will be required to
conduct tests to demonstrate to the Purchaser that each item of the plant is
capable of correctly performing the functions for which it was specified. These
tests may be conducted concurrently with those required under
commissioning sequence. The tests required shall specifically include the
following:
ii) Check on operation of all fans to ascertain level of noise and vibration.
iv) Check free rotation of gas heater and adjust seals, if necessary when
heater is up to working temperature.
v) Check operation of soot blowers and retraction gear and the sequence
control.
vii) Check operation of all variable speed drives throughout their respective
ranges on lime stone feeders etc. where applicable.
viii) Check operation of all motorized isolating valves both locally and from
the FGD control room.
ix) Check operation of all individual control loops in the FGD control system.
39
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
The FGD plants after completion of the above tests shall be put on trial
operation for a period of fifteen (15) days during which all necessary
adjustments etc. shall be made while operating over full load range enabling
the unit/ plant to be made ready for performance guarantee test.
i) During the Trial Operation period, the FGD Plant / System shall be
operated continuously for 360 hours (15 days) at various operating loads
as provided by the Purchaser and at various operating modes when firing
with the specified range of coal in the Boiler. Reliability Run of 72 hours
of un-interrupted operation at full load or near full load as may be
provided by the Purchaser shall be conducted during the Trial Operation
period. If there is any interruption in this 72 hours period of Reliability
Run, the same shall have to be attempted and demonstrated for
guaranteed 72 hours of un-interrupted running. In case of any
interruption of up to 4 hours in period of 360 hours (15 days) operation
(other than 72 hours of full load or near full load operation of Reliability
Run as described above), the period of interruption must be added to
360 hours; however, if cumulative period of interruption is more than 4
hours, then 24 hours will be added to 360 hours. In case the cumulative
period of interruption / down time of FGD Plant / System during Trial
Operation is more than 48 hours, then the Trial Operation shall be
considered as unsuccessful and the Contractor shall be asked to
demonstrate Trial Operation again, including the Reliability Run.
ii) The trial operation shall be considered successful, provided that each item
/ part of the FGD Plant/System can operate continuously at the specified
operating characteristics, for the period of Trial Operation with all
operating parameters within the specified limits and at or near the
predicted performance of the equipment/Plant. The Contractor shall
intimate the Purchaser about the commencement of Trial Operation and
shall furnish adequate notice to the Purchaser in this respect.
40
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
of the Purchaser to enable the latter to accord permission to carry out the
Performance Guarantee tests on the FGD Plant / System. However, minor
defects which do not endanger the safe operation of FGD Plant / System,
shall not be considered as reasons for withholding the aforesaid
permission.
i) The contractor shall guarantee that the equipment offered shall meet the
ratings and performance requirements stipulated for various equipment
covered in these specifications.
iii) The Contractor shall demonstrate all the guarantees covered herein
during functional guarantee/acceptance test. The various tests which
are to be carried out during performance guarantee/acceptance test are
listed in this Sub-section. The guarantee tests shall be conducted by the
contractor at site in presence of purchaser on each unit individually.
iv) All costs associated with the tests shall be included in the bid price.
Reject the equipment/ system/ plant and recover from the contractor
the payments already made.
OR
Accept the equipment/system/plant after levying liquidated damages
(LDs) as specified hereunder. The liquidated damages for shortfall in
performance shall be levied separately for each unit. The liquidated
damages shall be prorated for the fractional parts of the deficiencies.
41
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
SO2 removal in treated flue gas: Bidder shall guarantee that maximum
concentration of SO2 in treated flue gas at the exit of FGD for each unit shall
not exceed 1507 mg/Nm3 at 6% O2 on dry basis at 100% TMCR load with
corresponding conditions specified at clause no. 2.4.1 of the specification.
42
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
*Design and guarantee point conditions of FGD plant refers to the conditions
and requirements indicated at clause no. 2.4.1 of the specification.
12. Noise
i) All the plant, equipment and systems covered under this specification
shall perform continuously without exceeding the noise level of 85 dB
(95 dB for limestone crushers and 90 dB for wet ball mills) over the
entire range of output and operating frequency.
ii) Noise level measurement shall be carried out using applicable and
internationally acceptable standards. The measurement shall be
carried out with a calibrated integrating sound level meter meeting the
requirement of IEC 651 or BS 5969 or IS 9779.
43
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
Closing
Opening
44
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
2.13.5.1 The auxiliary power consumption shall be calculated using the following
relationship:
Pa = Ptg + TL
Pa = Guaranteed auxiliary power consumption
Ptg = Power consumed by the auxiliaries of the unit under test
TL = Losses of the transformers
While guaranteeing the auxiliary power consumption, the bidder shall
necessarily include all continuously operating auxiliaries. The auxiliaries and
their duty factor to be considered shall include but not be limited to the
following:
45
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
(ii) If FGD is out of operation during the boiler operation time as a result of
the Employer's decision, this time will not be counted as boiler operation
time for calculating the FGD availability,
(iii) Boiler operation hours will be counted based on the recorded boiler
operation hours and the recorded data will be made available to the
Contractor by the Employer.
46
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
47
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
48
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 2 (General)
In case, for reasons not attributable to the purchase, the time period taken by
the bidder for integration/ interconnection of FGD plant/ system with existing
thermal power units/ plant is more than the quoted/ mutually agreed plant
shutdown period, then liquidated damages shall be applicable for additional
shutdown period involved. The liquidated damages for each day of delay
beyond quoted/ mutually agreed period shall be applicable separately for each
unit as indicated under clause 2.15 below:
Notes:
i) Each of the liquidated damages specified above shall be independent and
these liquidated damages shall be levied concurrently as applicable.
49
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
SECTION 3.0
For each 500 MW unit, the hot flue gas tapped from outlet of existing induced
draft (ID) Fans shall be led to 2x60% FGD booster fans followed by the wet
limestone absorber. Treated flue gas from outlet of the absorber shall be
discharged to atmosphere through a new wet chimney of height 150 m
(purchaser to check for adequacy as per MoEF&CC’s requirement). During
unit start-up with oil firing or during any exigency, the FGD system shall be
bypassed and untreated flue gas shall be discharged to atmosphere through
existing chimney.
Other type of limestone wet absorber system viz. gas bubbling through the
slurry shall also be acceptable provided it is proven and standard scheme of
the bidder and same shall be subject to approval of the purchaser.
The absorber sump/ oxidation tank shall be adequately designed to give the
limestone enough time for formation of calcium sulphate and crystal growth.
Absorber sump shall be provided with adequate number of agitators for
agitating the slurry to ensure consistent concentration of absorbent and to
prevent settlement of solids.
Fresh limestone slurry shall be added into the sump by dedicated limestone
slurry transfer pumps to compensate for calcium carbonate consumed in the
absorber tower and the sump.
50
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
The emptying of the absorber shall be done by the gypsum bleed pumps into
the emergency storage tank for the purpose of inspection and maintenance.
Return pumps shall be provided for the refilling of absorber.
The limestone unloading, storage, crushing shall be common for both units of
the station. The limestone shall be received at power plant in trucks and shall
be unloaded and stored under covered shed at some convenient place in the
power plant. From storage yard, limestone to the FGD area shall be supplied
by trucks/ dumpers.
In the FGD area, there shall be two underground hoppers and limestone shall
be unloaded from trucks/ dumpers on underground hoppers/ paved area near
the hoppers. Adequate space shall be provided for movement of pay loaders/
bulldozers to facilitate dropping of limestone into unloading hoppers.
Limestone from unloading hoppers shall be fed to two sets of conveyor belts
through two vibrating feeders, one each placed under each unloading hopper,
and then to two limestone crushers via pent house. The crushed limestone
shall be supplied via belt feeders placed below crusher floor and bucket
elevators to the 2 Nos. crushed limestone bulk storage silo.
51
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
The gypsum dewatering and handling system shall be common for both units
of the station. Absorber bleed slurry from absorber sump shall be fed into
gypsum dewatering system through 2x100% capacity gypsum bleed pumps.
Gypsum slurry coming from two FGD units shall be fed into common2x100%
capacity primary hydro cyclones where it shall be classified and separated into
a solid enriched under flow and over flow with reduced solid content. The
underflow which contains the coarser gypsum particle shall be fed to 2x100%
capacity vacuum belt filters. The overflow shall be collected in a reclaim tank
and then taken to secondary hydro cyclone. The underflow of secondary hydro
cyclone shall be collected in a filtrate tank and then taken to the wet ball mill/
gypsum recovery system. Water from vacuum receiver tank(s) shall also be
recycled to the wet ball mill/ gypsum recovery system. The overflow from
secondary hydro-cyclone, as waste water, shall be collected in a waste water
tank.
Alternative scheme for gypsum dewatering & handling system as per proven
and standard practice of the bidder shall also be acceptable subject to
approval of the purchaser.
The gypsum from discharge of vacuum belt filter shall be collected in the
common storage area on ground floor beneath the floor of filters for further
transportation by trucks.
The waste water collected in the waste water tank of FGD system shall be
provided with adequate treatment and then disposed to existing ash handling
system.
Clarified water/ CW blow down water required for FGD plant shall be taken by
the bidder from the identified terminal point indicated in the specification.
Water shall be collected in a MS tank with epoxy painting of adequate capacity
from which process water requirement of the FGD system for various
applications shall be met through horizontal pumps provided with adequate
redundancy.
52
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
be identified by the Purchaser. The return hot water from FGD system shall
be terminated by the bidder at suitable terminal points on hot water sections
of DM cooling water piping.
The FGD system to be supplied by the bidder shall comprise of one FGD plant
for each unit with common facilities for limestone receiving, unloading,
storage, grinding, slurry preparation and gypsum handling & dewatering
system for both the units. A new wet chimney shall be provided for discharge
of treated flue gas into the atmosphere. Necessary modifications required in
the existing power plant systems for interconnection and integration of FGD
plant with the existing units/facilities are also included in the bidder’s scope.
The detailed scope of work is defined broadly hereunder but any equipment/
facilities/ services etc. not specifically defined herein but required for
successful completion/ commissioning of system shall be deemed to have
been included in scope of supply of bidder without extra cost to the purchaser.
The bidder’s scope of work shall include, but not limited to, the following:
b) Flue gas duct work for each FGD plant, from existing ID fan discharge
duct to inlet of booster fans, from discharge of booster fans to inlet of
absorber and from outlet absorber to the new wet stack. Ductwork
shall be complete with all structural supports, stiffeners, quick opening
access doors, flanged duct connections, corrosion protection lining for
duct downstream of the absorber& for wet flue(s), thermal insulation,
test connections, etc.
For 500 MW unit, two (2) nos. axial booster fans each of capacity
60%with constant speed motor drive and blade pitch control for each
FGD plant along with oil cooling system comprising of lube oil tank, 2 x
100% lube oil pumps, coolers, duplex oil filters etc. and other accessories
as required.
53
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
c) One (1) mist eliminator wash water tank along with 2 x 100% mist
eliminator wash pumps (if applicable).
d) One (1) no emergency slurry storage tank (common for both units to
store slurry content of one absorber. The emptying of the absorber
sump shall be done by the gypsum bleed pumps. Tank shall be
suitably lined, provided with agitators and 2 x 100% slurry transfer
pumps to pump slurry back to absorber in 8 hour (max).
54
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
g) Two (2) x100% gypsum bleed pumps for each absorber taking suction
from the absorber sump.
iv) Limestone Unloading, Crushing & Storage System
b) Lube oil system for ball mills comprising of lube oil tank, 2 x 100% lube
oil pumps, coolers, duplex oil filters.
55
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
ii) As the present work involves retrofitting of FGD plant, it shall be the
responsibility of the contractor to modify, rectify and strengthen the
existing structures at the interface with the new FGD plant as per the
requirements.
56
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
iv) The scope of civil, structural and architectural works for retrofit of wet
limestone FGD plant shall include the following but not limited to:
c) One twin wet flue chimney of RCC construction of height 150 m (for
2x500 MW units) with flue liner at downstream of FGD system along
with rake & pinion type elevator and wet chimney condensate
collection system etc. Purchaser to check for adequacy of the
indicated height as per MoEF&CC’s requirement. Alternately, in
case existing chimney is to be used, the scope of work shall include
retrofitting works of providing corrosion protection lining on chimney
flues and wet chimney condensate collection system, etc. as
required.
57
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
The buildings shall be of RCC with brick wall cladding. The buildings
shall have adequate circulation space for inspection & maintenance
purposes and shall have separate rooms for various facilities and
other civil amenities like office room, store, toilets etc. as per the
requirements of the system. The buildings shall have suitable
hoisting arrangement for handling the equipment during erection and
maintenance as required.
j) Construction of all cable trenches, pipe & cable racks, trestles and
their foundations, RCC culverts and concrete pipes for underground
facilities.
58
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
n) Any other civil & structural work required or necessary for successful
commissioning of the FGD Plant.
There will be mainly four areas of the FGD equipment system viz. limestone
unloading & crushing; limestone slurry preparation; absorber area and
gypsum dewatering/ handling systems. The purchaser shall provide two (2)
nos. 11/6.6kV supply feeders (as applicable) from his switchgear (preferably
from two different sources). Further distribution at 3.3/0.415kV level shall be
done by the bidder for entire FGD plant. Tentatively, the scope of electrical
works shall include but not limited to the following:
i. HT Switchgears:
a) Two (2) no. 11/0.433kV or 3.3/0.433kV or 6.6/ 0.433 kV cast resin dry
type/ Oil filled transformers of adequate rating located at absorber
area of FGD Plant.
b) Two (2) no. 11/0.433kV or 3.3/0.433kV or 6.6/ 0.433 kV, cast resin dry
type/ Oil filled transformers of adequate rating located at “Limestone
unloading, storage & crushing facilities”
c) Two (2) no. 11/0.433kV or 3.3/0.433kV or 6.6/ 0.433 kV, cast resin dry
type/ Oil filled transformers of adequate rating located at “Limestone
slurry preparation facilities”.
d) Two (2) no. 11/0.433kV or 3.3/0.433kV or 6.6/ 0.433 kV, cast resin dry
type/ Oil filled transformers of adequate rating located at “Gypsum
handling facilities.”
59
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
iv. As the present work involves retrofitting of FGD plant, the power supply
arrangement (transformers/ 415V switchgear) for different areas can be
clubbed together provided both the areas are located nearby depending
upon the layout.
vi. Local push button stations for all drives and local motor starters for
ventilation fans.
60
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
vii. Connections
a) Connections from 11/6.6 kV source of supply (purchaser) to 11/6.6 kV
switchgear located in switchgear room for FGD Plant shall be through
11/6.6 kV Cables.
b) Connections from 11/6.6/3.3kV switchgears to 11/0.433 and
3.3/0.433kV or 6.6/0.433kV transformers shall be through Cables/ Bus
ducts.
c) Connections from 11/0.433kV and 3.3/0.433kV or 6.6/0.433kV
transformers to 415V LT switchgears shall be through LT Bus ducts.
d) 11/6.6/3.3kV cables shall be XLPE insulated, FRLS PVC sheathed.
f) LT power cable shall be 1.1kV grade XLPE/ PVC insulated and FRLS
PVC sheathed and control cables shall be 1.1kV grade PVC insulated
and FRLS PVC sheathed
viii. Supply, laying and termination of all required power, control and
instrumentation cables, conductor and LT bus duct.
ix. Complete cable facility including cable laying along with cabling
accessories, cable trays with supporting, structures, termination and
joining kits, cable trenches, overhead trestles, etc. as required for the
cables.
x. 220 V DC system
220 V DC, lead acid (Plante)/ Ni-Cd battery (Pocket plate High discharge
type) with two (2) nos. float cum boost chargers and associated DC
distribution board to be provided (separately, if required) for absorber
area of FGD plant, “limestone unloading, storage & crushing facilities”,
“limestone slurry preparation facilities“ and ”Gypsum handling facilities”.
61
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
iii) One (1) 24" redundant server based engineering work station common
for both units.
iv) One (1) engineering laptop with master software.
v) One A4 size coloured laser jet printer and One no. A3 sized Dot matrix
Printer
vi) Local Control Panel in limestone unloading and feeding plant area for
control of conveyors, vibrating feeders, crushers etc. with interface to
FGD PLC.
vii) Local instruments, such as pressure/ temperature/ level/ flow gauges,
switches, transmitters etc.
viii) Special instruments viz. SO2 measuring instrument/ analyser at FGD
inlet & outlet, vibration analyser, calibration instruments, pH measuring
instrument/ analyser.
ix) Continuous emission monitoring system (CEMS) comprising of
analysers and associated items for measurement of SOx, NOx, CO 2,
Mercury, Particulate emission (dust density/ stack opacity) monitor, stack
flue gas ultrasonic flow meter etc. for chimney emission monitoring.
x) Interlock, and Protections.
xi) Closed loop control system.
xii) Hardwired and soft link interfacing with the existing unit DCS as required
to ensure safe, reliable and integral operation of the FGD system along
with the respective Unit operation.
xiii) Instrument hook up material, erection hardware, impulse tubing/ piping,
fitting, racks, stanchions, enclosures, junction boxes etc. for bidder
supplied instruments/ analyzers/ devices etc.
62
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
3.2.5 One (1) no. process water tank common for both units (4 hours capacity) along
with 2 x 100 % process water pumps along with associated piping valves &
fittings.
3.2.6 2x100% DM booster pumps for DM water cooling of FGD system equipment.
3.2.7 All drain sump pits along with 2x 100% sump pumps for absorber area (with
agitators, if required), gypsum dewatering area, lime stone slurry preparation
area etc.
3.2.9 Complete slurry line flushing system including surge tanks and 2x100%
booster pumps.
3.2.10 The limestone conveying system and gypsum conveying system (if applicable)
including conveyor drives, idlers, belting, pulleys and necessary protection
devices.
3.2.11 Two (2) nos. limestone sampling units, one for uncrushed limestone before
crusher system and one for crushed limestone after crusher system complete
with all accessories and auxiliaries etc.
3.2.12 2x100% indoor, reciprocating air compressors and 2x100% air dryers,
common for both units, of suitable capacity and discharge pressure complete
with accessories shall be provided to cater the requirement of instrument air
for valves etc. The service air for various buildings and facilities of FGD system
shall be taken from existing service air system, tapped from a terminal point
identified by the purchaser.
3.2.13 The structural steel work for mechanical equipment such as conveyor support
frame, deck plates, chutes.
3.2.14 All hoisting equipment, tools and tackles required for removal and
maintenance of rotating and non-rotating equipment of entire FGD system.
This shall include structures, gantries, hoists, trolleys and supporting steel
structure.
3.2.15 Complete service and instrument air distribution system for the entire FGD
system.
63
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
3.2.16 Complete wash down hose system for entire FGD system with 15m hoses
along with connections.
3.2.17 Thermal insulation of all flue gas ducting, gas to gas heat exchangers, booster
fans and scrubbers etc. as applicable.
3.2.18 One (1) number passenger cum goods elevator of minimum capacity 1000
kgs for each absorber for easy access & movement of men & material.
3.2.19 Interconnecting piping, fittings, valves, nuts and bolts, mountings, gaskets,
supporting arrangement, pipe anchors, pipe hangers, trestles, vibration
isolation arrangement, anchor bolts, foundation plates etc. as required for lime
preparation, absorber and gypsum handling area and for completion of the
FGD system.
3.2.20 Ventilation system for all buildings including conveyor gallery and air-
conditioning of FGD control room.
3.2.21 Fire detection, protection & alarm system for complete FGD system and its
integration with existing system.
3.2.22 Service and potable water system for the complete FGD system.
3.2.23 Vibration monitoring system for booster fans and crushers including vibration
probes, transducers, junction boxes, vibration monitoring racks and
interconnecting cables.
3.2.24 Mandatory spare parts for trouble free operation of the FGD plants as included
in the specification.
3.2.25 Supply of commissioning spares and all lubricants, greases and consumables
etc. as required during erection, testing, commissioning and till handing over
of the FGD system
3.2.27 One set of special tools and tackles including testing, calibrating and
measuring instruments required for erection, assembly, necessary tools and
tackles required for operation and maintenance of all equipment/ systems
covered under the scope of bidder shall be supplied. These shall not be used
for erection/ commissioning purposes and shall be in unused condition. A list
of such special tools and tackles shall be submitted along with the bid. The list
shall include wrenches, spanners and screwdrivers, special bolts and or other
accessories required for proper assembly, field welding equipment, necessary
special wrenches and jigs and tools for disassembly and reassembly of pump
rotors, and repacking glands, tools and tackles considered necessary for
proper erection, operation and maintenance of the instruments and one (1)
repair kit for field patching of cracked rubber lining along with sufficient
patching material.
64
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
3.2.31 Any other item not specifically mentioned in the specification, but considered
necessary for safe and efficient operation of the system.
65
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 3 (System Description and Scope)
3.3.2 Exclusions
i) Firefighting system and Equipment (unless specifically included in
scope).
ii) Station wide LAN.
iii) Receipt, unloading and storage of limestone at plant site.
66
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
SECTION 4.0
MECHANICAL WORKS
4.1.1 General
All gas ducts required within the FGD system and for connection of FGD system
to the boiler gas paths shall be provided and shall conform to the requirements
specified herein.
i) Flue gas ducts tapped from discharge duct of existing ID fans to inlet of
booster fans and from discharge of booster fans to inlet of absorbers
shall be of all welded construction of steel plates of suitable thickness
but not less than 7 mm and shall be adequately stiffened by means of
rolled sections. Suitable stiffening to prevent sagging, distortion,
excessive vibration and pulsation under any operating conditions shall
be provided.
ii) The flue gas duct from outlet of Absorber to the new wet stack shall be
made of STEN-I or equivalent of minimum 9 mm thickness. Alternatively,
the ducts shall be made of 7 mm thickness carbon steel provided with a
flaked glass lining, if the contractor has proven experience of the same.
Lining shall be attached properly to the base to ensure that the base
material does not come into contact with the corrosive gases under any
circumstance. Sufficient overlap of the lining material shall be provided.
Suitable stiffening to prevent sagging, distortion, excessive vibration and
pulsation under any operating conditions shall be provided.
iv) All flue gas ducts shall be designed either for pressure or vacuum of +/-
660 & -150 mmwc (g) respectively at 67% yield strength or for maximum
conceivable pressure of Booster fan whichever is higher.
v) The velocities of flue gas in the ducts shall not exceed 15 m/sec. The
design shall ensure equal distribution of flow. Flow distribution vanes
shall be provided in ducts wherever required. Bends provided shall be
smooth to streamline the flow. Cross section and flow direction changes
must not allow creation of dead spaces with possibility of fouling. Model
studies of duct work may be carried out for optimum flow distribution with
minimum pressure loss.
67
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
viii) The duct work upstream of absorber and the quenching/gas cooling zone
shall be designed to withstand the temperature rise associated with the
failure of air pre-heater at full load operation.
ix) The design of the duct work and supports shall ensure freedom from
vibration and noise.
xii) Thermal insulation shall be applied to all air/ gas ducts to comply with
the requirements as specified elsewhere in this specification.
xiii) Acoustic insulation shall be used, if required, in gas ducts to restrict the
noise level to specified values.
xiv) The duct layout shall ensure that there is no accumulation of acid mist
on the duct floor. The absorber outlet duct shall not have any horizontal
section for this purpose.
xvi) All ducts shall have a sufficient slope with respect to horizontal so that
any chance of accumulation of ash particles or water in the duct can be
avoided under all normal/abnormal operating conditions. Drainage
facility shall be provided for all ducts where significant quantities of
water are liable to collect under emergency conditions. The ducts shall
be routed such that satisfactory condensate drainage is ensured. The
inlet duct shall have minimum 10 degrees downward slope in the
direction of absorber. Any material collected in the inlet duct shall be
taken to reaction tank.
68
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
xvii) Drain fittings shall be sized to pass the expected drain flow. Drain fittings
shall be fabricated of alloy material (at least Hastelloy C or better) or FRP
if surrounding requirements can be fulfilled. Additional drains shall be
provided based on results of the flue gas flow model study to be
furnished by Contractor. Drains shall be returned to the FGD drain pit
or the absorber sump to be constructed by the bidder for the purpose.
The drain scheme shall be approved by the purchaser. No drain line shall
be sized below 25 mm ID. All drain lines shall be provided with two
isolating globe valves in series.
xviii) Access doors shall be provided to permit access to all duct sections for
inspection and maintenance of duct work and ductwork accessories
including expansion joints and dampers. They shall be of adequate size,
gas tight with bolted closing arrangement and shall be of hinged type.
The required ladders/staging for maintenance inside the duct shall be
included. Dampers shall be accessible from both directions by way of
associated inspection doors in near vicinity.
xix) The ducting shall be complete with required number of expansion joints,
hangers, supports, flanges, gaskets, access platforms, ladders etc.
Expansion joints shall, where necessary, be provided with internal plates
to prevent and to eliminate the deposition of dust in the joints. A capped
nipple type connection shall be provided at the bottom of all expansion
joints to facilitate air cleaning.
xx) A series of test points shall be arranged in the duct work at approved
position so that the distribution of gas, can be tested.
xxii) Particular attention shall be given to thermal expansion of the ducts and
steel structure, in order to avoid inadmissible forces to connected
equipment. Thermal expansion shall be accommodated by means of
expansion joints with an internal guided plate. The ingress of fly ash
and FGD by-product into the expansion joint shall be prevented. Sliding
bearing supports shall be provided as required to permit the thermal
expansion of ductwork. The material chosen for expansion joints shall
suitable for the duty conditions and the corrosive atmosphere of the FGD
system and shall be field proven for similar applications. The expansion
joint shall have a minimum guaranteed life of not less than 20000 hrs. of
operation.
xxiii) All ductwork provided by Contractor shall have external stiffeners only.
No internal stiffeners or bracing are allowed. External ductwork stiffeners
shall be spaced uniformly.
69
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
4.1.2 Dampers
Alternative arrangement of dampers viz. inlet tap off to individual booster fan,
as per proven and standard practice of the bidder, shall also be acceptable
subject to approval of the purchaser.
The bidder shall furnish a list of dampers with their purpose and size, which
are provided with servo-drives for remote control. All damper shall be
motorized and provided with actuators and the complete link mechanism
connecting the dampers and their actuator. Such dampers shall also have
provision for manual operation during maintenance.
ii) The dampers shall be of reputed make. The blades and frames of the
dampers provided at the inlet and outlet of Booster fan shall be made of
carbon steel.
iii) The operation of dampers shall be suitably interlocked with booster fans,
ID fan and existing controls of the unit to prevent mal operation leading
to damage of the unit or FGD system.
iii) Gas dampers shall be capable of being operated and be tight in the
closed position under the maximum differential pressures without
bending/warping or seizure, and shall be fitted with locking devices in the
fully open and closed positions. The Bidders shall state the special
features provided to make them gas tight to enable maintenance of
equipment whilst the steam generator is in service.
70
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
vii) All dampers shall be so arranged to facilitate local manual operation from
a gallery or floor level. The operating gear shall be fitted with a graduated
indicator and shall be designed such that the damper may be retained in
any position. The force required for manual operation of the gate shall
not exceed 35 kg (max.) at the rim of the hand wheel. The isolating
dampers shall, in addition, be fitted with a locking device in the fully open
and close position. All powered dampers shall also have provision for
manual operation during emergency and maintenance along with
graduated local position indicator.
viii) Dampers shall close tightly and operate easily and smoothly without
bending or fluttering under all operating conditions.
ix) The actuator shall be equipped with positioning switches for both end
positions, torque switches for both function directions, hand wheels for
emergencies and mechanical interlock for maintenance work. In
addition to this limit switches shall be provided with all dampers to
indicate fully open and fully closed positions. These limit switches shall
be independent of those provided with the drive units. Limit switches
shall be provided at each end of travel and shall directly indicate the
blade position.
x) All the dampers shall be so located in flue gas paths that buildup of grit
behind the damper blades is reduced to a minimum.
xi) Weather hood to prevent rain water entry and accumulation shall be
provided at damper top.
xii) All dampers shall be easily accessible from both outside and inside of
the ducts. For this purpose, Contractor shall furnish access platform (s)
at each damper and its drives such that all components are fully and
safely accessible by stairs. Drives shall move with dampers as the unit
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
expands and contracts. Platform size and location shall be based on the
damper manufacturer’s recommendation subject to owner’s acceptance.
The access from insides of the ducts shall be done by providing
inspection doors at the gas ducts in close vicinity to the dampers from
both sides.
Two gas booster fans, suitable for producing adequate draft for flow of flue
gases through FGD system under all operating conditions, shall be provided
for each FGD plant. The Booster Fans located downstream of the ID Fans in
the inlet duct to Absorber shall be capable of handling the pressure drop in the
FGD system & ducting and maintain required pressure at inlet to the new
chimney over the entire load range with any one or both Booster fans in
operation in conjunction with one or both ID fan in operation while firing the
specified range of fuels. Fans shall be complete with drive motor, coupling,
base plates fixing bolts and nuts. The booster fans shall meet the following
requirements:
i) Capacity of each fan shall correspond to 60% BMCR flow. Over and
above value thus calculated, following margins shall also be applied for
sizing the fan:
However, the best efficiency point for the fans shall be at unit MCR. The
bidder shall furnish the fan sizing calculations for approval of purchaser
during detail engineering.
ii) The gas booster fans for 500 MW size unit shall be constant speed, axial
flow centrifugal type. The maximum speed of the fans shall be limited to
750 rpm. The booster fans shall be capable of fully meeting the pressure
drop of the FGD plant and the associated ducting/dampers/fitting under
all loading conditions. Booster fan shall provide for sufficient positive
pressure at the inlet of wet chimney so as to facilitate effective discharge
of wet flue gases into the atmosphere through the wet chimney.
iii) The design shall incorporate such materials as to ensure reliability and
high availability of the fan service under adverse conditions of corrosion
in the flue gases. The dust concentration in flue gases is expected to be
in the range 50- 200 mg/Nm3. The fan casing and impeller blades shall
be provided with suitable renewable wear resistant liners of proven
design. Suitable proven arrangements shall be provided for prevention
of corrosion of fan components.
iv) The design of fans shall ensure prevention of corrosion of areas coming
in contact with flue gases, prevention of buildup on blades and erosion
of blades and prevention of entrance of flue gas and condensate into
interior of rotor and hub. All stationary parts coming in contact with flue
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
v) Booster fan components such as blades, hubs, casing etc. shall be able
to encounter the high dust burden of the order of 200 mg/Nm 3. The
minimum wear life of Booster fan components shall not be less than
25000 hours of operation from the date of commissioning.
vii) The fans shall be suitable for parallel operation with equal load sharing.
Unbalance during operation shall be signaled through suitable
indication/alarm. The fans shall be suitable for stable operation
continuously at all loads from 30% to 100% of the fan capacity.
viii) The fans shall be capable of operating satisfactorily in series with existing
ID fans without any problem for complete range of operation
ix) Fans shall be provided with blade pitch control regulation mechanism.
The flow control shall be suitably interlocked/ integrated with existing
boiler controls.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
xi) The fan shaft shall be designed in such a way that critical speed shall
not fall within 125% of the operating speed. The fan should be statically
and dynamically balanced.
xii) Fan induced duct vibration due to flow pulsations shall be avoided
through suitable design.
xiii) Overhang type impeller designs shall not be accepted. Shaft shall be
carried in bearings on either side of impeller and shall be independent of
casing.
xv) Noise shall be limited to maximum 85 dbA for all equipment (except of
90 dBA for wet balls mill and 95 dBA for limestone crushers) as
measured at a distance of 1m and at a height of 1.5 meter
xvi) For forced oil lubrication arrangement (if envisaged) for fans and drive
motors, the complete pumping system with storage tanks, thermostats,
coolers, strainers, filters, sight glasses, pressure gauges and separate
pressure switches, flow gauges, differential pressure switches, dial
thermometers and separate temperature switches, flow control valves
etc. shall be furnished. The lube oil pumps and filters shall be 2x100%
capacity with proper isolating valves etc. The system shall also include
controls, starters, ammeters for lube oil pump motors, interlocks and
protection for motors etc. for each fan and motor.
xvii) Fan bearing shall be provided with oil bath to prevent damage in case of
complete loss of plant auxiliary power when the fans must coast down
without power. Adequate numbers of duplex Pt-RTD (100 ohms at 0
degree Celsius) or thermocouples and one no. temperature indicator
shall be provided for each bearing.
xviii) Fully wired interlocks and control panels common for both the fans shall
be provided to the approval of purchaser. All necessary annunciations
shall be provided for common annunciation on the FGD OWS for any
trouble in the system.
4.3.1 Absorber
i) Two (2) nos. wet limestone absorber shall be provided (one for each unit)
for absorption of SO2from the flue gases. The absorber shall be designed
for 100% BMCR conditions with worst coal. The maximum flue gas flow
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
vi) Sufficient protection shall be provided for the base of the tank to prevent
mechanical damage, particularly during maintenance. The material of
75
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
vii) The absorber and oxidation tank shall be made of minimum 7 mm thick
carbon steel. The absorber tower, oxidation tank, absorber internals &
other parts, absorber outlet duct shall be provided with minimum 2 mm
thick lining/ cladding of SS 317 LMN / Alloy 31/ Hastelloy C22/ C 59/
C276 or equivalent. Special precautions shall be taken to prevent
failures due to blistering, debonding and wear due to abrasive slurry
which enables to keep time interval for necessary inspection and/or
repairs in compliance with the duration of overhauls (period 5 years).
viii) The absorber slurry tank shall be designed for 6 minutes retention based
on the design absorber slurry flow rate.
xi) The bidder shall guarantee the operation of scrubber along with mist
eliminators without fouling or plugging continuously for the period of
20,000 hours without cleaning which requires FGD shutdown. Access
for possible inspections of the mist eliminator section shall be provided.
xii) Provision shall be made for automatic spray of quenching water at the
inlet to the absorber, in case the gas temperature exceeds the design
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
xiii) The absorber sump shall be located above ground level so that its
content can be completely discharged. Suitable provision shall be made
for complete transfer of slurry in absorber sump to the common
emergency slurry tank.
xiv) The design of and materials selected for all nozzles shall be such that
Rapid wear, encrustation and plugging is avoided. Hollow cone or spiral
spray nozzles made of silicon carbide or equivalent shall be used.
xv) The design of the external steel structure of the absorber must allow
access to the whole surface of the absorber sheet, including the spaces
beyond the service platforms (possibility of suspensions etc.).
b) The first mist eliminator (bottom) shall be located at least 5 feet above
the last slurry recycle header (top) in the absorber module. For vertical
mist eliminators, the spacing between the top of the first and bottom
of the second mist eliminators should be at least 6 feet. The superficial
gas velocity in the mist eliminator area should not exceed 10 ft/sec for
vertical gas flow mist eliminators and 18 ft/sec for horizontal gas flow
mist eliminators.
c) The type of chevrons used for both the first and second mist
eliminators shall have continuous blades (baffle type mist eliminators
with separated blades are not acceptable). The exit section of the first
mist eliminator chevron shall be constructed with a straightening
section and/or oriented such that the flue gas leaves in the essentially
the same direction as it entered the mist eliminator.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
nozzles used in the wash system shall be full cone spray nozzles with
no more than a 90 (degrees) spray angle, and they shall not use any
moving parts to achieve the spray pattern. The overlap from adjacent
wash nozzles shall provide a minimum of 150 percent coverage (on
average) of the mist eliminators. The wash nozzles shall be located
no more than 36 inches from the mist eliminator surface.
xvii) In case the multi spray absorber, limestone slurry required for absorption
of SO2 shall spray in the tower at the spray levels provided, with minimum
distance of 1.5 m between each level, through suitable nos. of inlet
connections. The spray system consisting of headers, laterals and
nozzles etc. shall be designed to provide for uniform distribution of
limestone slurry across the entire cross-section of the tower. The
nozzles shall be designed to provide satisfactory spray pattern over a
wide range of limestone slurry loading in the tower. The nozzles shall be
of non-clogging type, and their design shall be suitable to handle
limestone slurry solution.
xix) The absorber tower shall be designed as to allow for easy inspection, to
the cleaning and repair. Adequate number of viewing ports with flushing
arrangement shall be provided to view the condition of absorber internals
and process taking place during operation. Due consideration shall be
given to the wind loading and appropriate stiffening shall be provided on
the tower to prevent failure or bucking when empty or when subject to
vacuum as per relevant Indian/equivalent standards.
xx) The absorber tower shall be provided with manholes, ladders,
maintenance scaffolding, hand railing etc. Each absorber shall have
access door above each spray level, between the mist eliminator section,
in the inlet duct and outlet duct. The supporting structure for limestone
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
slurry system and clear water distribution systems, mist eliminators shall
be designed to ensure unrestricted upward flow of flue gas and
downward flow of water. Supporting structure shall also be made of
corrosion resistant materials. Lightning arresters and grounding
connection shall be provided on each tower.
4.3.2 Mist Eliminator Wash Water Supply System
i) Clarified water shall be used for cleaning of mist eliminators and the
system shall be provided unit wise. One no. service water/ clarified water
storage tank and 2x100% capacity horizontal centrifugal pumps shall be
provided for intermittent cleaning of demisters/ mist eliminators of each
absorber. The capacity and head of the pump shall be as per spray
cleaning requirement of the mist eliminators with adequate margins.
ii) The storage capacity of the tanks shall be as per requirement of service
water for intermittent cleaning of the mist eliminators. Input water to the
storage tanks shall be supplied from process water tank. The tanks shall
be made of mild steel and their design shall conform to Indian Standard
or equivalent. The tanks shall be complete with inlet/outlet connections,
overflow and drain piping connections, level indicator, manholes, air
vents, and ladder etc. Level switches/ instruments shall be provided on
the tanks for alarm annunciation and control interlock of demister
cleaning pumps. Continuous water level reading of the tank shall be
provided in the FGD control room.
iii) The demister cleaning pumps shall be of centrifugal type having
horizontal design and shall be suitable for outdoor installation. However,
protection sheds shall also be provided for these pumps.
iv) The pump casing, gland and stuffing box shall be of 2.5% Ni Cast Iron to
IS:210 Grade FG 260 or equivalent. The impeller, wearing rings (as
applicable) shall be of Stainless Steel316 grade and shaft & shaft
sleeves shall be of SS-410 grade.
v) The materials of construction of piping, valves and fittings etc. shall be
of proven type as per duty involved and shall be subject to approval of
the purchaser during detail engineering. The pump discharge piping up
to the top of the scrubbers shall be of mild steel.
4.3.3 Slurry Pumps
i) Each absorber shall be provided with adequate number of limestone
slurry recirculation pumps with minimum 1 standby pump, 2 x100%
gypsum bleed pumps for supply of gypsum slurry to gypsum dewatering
system, two (2) x 100% make up slurry pumps for each absorber,
2x100% emergency slurry transfers pumps (if required) and 2 x 100%
slurry recirculation pumps for each mill. Other pumps required as per
system requirement shall also be included.
ii) The pumps shall be of horizontal type and designed for continuous
operation. The pump shall be single stage centrifugal type capable of
delivering the rated flow at rated head with margins as specified in the
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
respective clauses. The slurry concentration in the pump shall not
exceed 30% by weight.
iii) The slurry pumps shall be provided with design margin of minimum 10%
in the rated flow and minimum 10% in the rated head calculated at duty
point of the pump.
iv) All the slurry pumps shall be provided with motorized suction and
discharge valves. In addition, flushing water tines with motorized valves
shall be provided for each pump for automatic flushing of the pump after
each shut down. The flushing water for the pumps shall be taken from
the process water supply.
vii) All the pump wear parts in contact with the slurry shall be provided with
replaceable rubber/elastomer liners suitable for the fluid handled. The
material and thickness of the liners shall ensure a minimum service life
of 2 years before replacement. All the wear parts of the pump shall be
guaranteed for a minimum wear life of not less than 14000 hrs.
viii) The pump shall be provided with seals of proven type and shall be
designed for minimization of seal water consumption. The shaft shall be
supported on heavy duty ball/roller bearings.
ix) The design and construction of the various pumps shall meet the
requirements of the horizontal centrifugal pumps described elsewhere in
the specification.
4.3.4 Oxidation Air blowers
i) The air blowers shall be provided to supply the oxidation air for oxidizing
calcium sulphite (CaSO3) to more stable and harmless compound
calcium sulphate (CaSO4). 2x100% capacity oxidation air blowers shall
be provided for supplying oxidizing air for oxidation of limestone slurry in
the absorber sump tank of each FGD Plant. Minimum redundancy of
10% on oxidation air nozzles/ spargers shall be provided. Air supply
headers shall be made of FRP or Carbon Steel with rubber lining
(minimum 10 mm natural rubber lining), corrosions and erosion resistant
in the inner and outer side (Silicon Carbide coating on metal/FRP surface
exposed to slurry).
.
ii) The oxidation air blowers/ compressors shall be of centrifugal/rotary/
positive displacement type and supplied with base frame with shock
absorbers and mounting bolts, intake filter with hood, silencers, safety
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
valves and check valves etc. The blowers shall be of sturdy construction
with various components made of suitable corrosion resistant material.
iii) The air blowers shall be sized to supply at least 2.5 times the
stoichiometric air requirement for spray tower process & at least 4.0
times the stoichiometric air requirement for Bubbling Type process or the
actual requirement whichever is higher under design condition with 10%
choking/ blockage each of the oxidation air nozzles. Further, a margin of
10% each on capacity and head of the blower shall be considered under
above condition.
iv) The air blower shall be compact and simple in design requiring minimum
number of spare parts. The blower shall be designed for continuous
operation and shall be of water-cooled/air cooled type. The rotor shall
be ground all over and accurately machined. The rotor blades shall be
made of chrome steel or equivalent and shall move freely and smoothly
in the rotor slots. The shaft shall be of hot rolled steel or equivalent
accurately ground, polished and keyed to the rotor. It shall run in
precision heavy duty roller bearings. Lubrication system provided shall
be designed such that visual checking of lubricant level is possible. The
blower shall be provided with water jackets for cooling the bearings and
the casing and prevent excessive heating of parts. The casing shall be
of grey cast iron conforming to IS:210 grade 25 designed for the duty
specified. The cooling water jackets shall be readily accessible for
maintenance purposes. Provision shall be made to shut off the blower
automatically should the level of the lubricating oil falls below the design
value. The blower shall also shut-off automatically whenever the
pressure of the cooling water supply line falls below a preset value. The
first fill of the lubricant shall be given by the supplier.
v) The roots blower shall be of twin lobe type with grey iron casing with alloy
steel heat treated and lobes. The shaft shall be of high carbon steel
accurately ground running in roller bearings. The bearing on both drive
and end gear end and gears shall be oil lubricated. Both shafts shall
have lip and labyrinth seals to prevent leakage of oil and air respectively.
vi) The base plate for the blower, driver V- belt, pulleys, coupling, guards,
pressure relief valves, air filter and silencer shall be included.
vii) The blower shall be driven by an electric motor either directly coupled via
flexible coupling or through v-belt drive. The bidder shall quote for both
the alternatives. The belting system in the case of v-belt drive shall be
provided with a heavy screen guard for ensuring safety and the motor
shall be mounted on slide rails for adjustment of belt tension.
viii) One cleanable, dry, air intake filter cum silencer to prevent dust and other
atmospheric impurities from entering the blower shall be provided for
each blower. The silencer shall reduce the noise level to 85 decibels at
a distance of 1 meter from the blower. The filter area shall be at least
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
twice that of the inlet pipe area. The filter shall be suitable for removing
dust particles down to 5 microns size.
4.3.5 Agitators
Each limestone slurry handling tank and sump shall also be provided with
adequate number of agitators including for redundancy.
In case bidder offers side entry agitators, minimum four (4) number agitators
shall be provided for each absorber slurry sump to promote mixing, maintain
a uniform slurry concentration. All agitators shall have minimum 6mm rubber
lining on shaft and impeller. The contractor shall demonstrate that n-1 number
of agitators are sufficient to avoid the slurry settlement in the absorber tank in
case of one agitator under breakdown (n-total no. of working agitators).
i) From the terminal point for process water/ clarified water (or any other
type of water), the bidder shall draw water to separate water storage
tank(s), designed to store 4 hours of total water required for the entire
FGD process (including absorber system, mist eliminator wash system,
limestone grinding and slurry preparation system and gypsum
dewatering system etc.) for the FGD plant. The storage tank shall be of
mild steel and shall be designed, fabricated, erected and tested in
accordance with the IS:803, latest edition unless otherwise stated.
ii) Process water shall be pumped from these tanks using 2 x 100% pumps
to cater to the water requirement of the entire FGD system. The capacity
of the pumps shall be such that total capacity of working pumps shall
meet the process water requirement of the unit operating at maximum
load with 10% margin.
iii) The design and construction of the various pumps shall meet the
requirements of the horizontal centrifugal pumps described elsewhere in
the specification.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
- Two (2) x 100% (one for each unit) limestone slurry storage tanks.
- One (1) no. (common to both units) emergency slurry tank
- Two (2) nos. (one for each unit) emergency quenching water storage
tank
- Two (2) nos. (one for each mill) slurry recirculation tank for wet ball
mills
- One (1) no. (common to both units) reclaim water tank
One (1) no. (common to both units) filtrate tank
- Two (2) no. (common to both units) waste water tanks
Any other tank(s) required as per process requirement and for
completion of the FGD system shall be provided by the contractor without
any extra cost to the purchaser.
ii) All tanks except those specified otherwise shall be of mild steel. These
shall be lined with suitable material capable of satisfactorily withstanding
the respective fluids to be handled by these tanks. Each tank handling
limestone slurry shall be complete with stainless steel (SS) motor driven
agitators, dilution water inlet and limestone dosing connection. All tanks
furnished by the Bidder shall be designed to be suitable for operating
conditions. The tanks shall be provided with inlet and outlet connections,
hand holes, manholes, connections for level gauges, vents, drain and
overflow, etc. as may be required. All the tanks including chemical
solution tanks shall be provided with drain valves and piping, overflow
piping and the same shall be led to the nearest drain sump. All the non-
pressure tanks shall be provided with removable hinged type top covers
in two halves.
iii) For volume/ sizing calculation of limestone slurry storage tanks, the solid
concentration (by weight) in the slurry shall be considered not more than
20% or actual required whichever is lower.
iv) The slurry handling storage tanks shall be equipped with sufficient
number of agitators, to avoid settling of limestone, as per the proven
practice of the supplier. The agitators shall be designed to meet the
requirements stipulated elsewhere in the specification.
v) The emergency limestone slurry tank shall be sized to contain the
complete slurry of one absorber tank at its maximum level.
vi) All tanks/ pressure vessels shall be designed and tested to withstand 1.5
time the design pressure. Pressure vessels shall conform to IS: 2825
and storage tanks to IS: 803/BS: 2594.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
recirculation pump, feed pump, gypsum extraction pumps for each FGD
plant.
ii) The elevators shall be designed as per latest edition of IS: 14665 (all
parts). All mechanical and electrical operating devices and Trailing
cable shall be designed for outdoor operation with dusty and high
humidity conditions. Additionally, all mechanical and electrical
components of the elevator shall be designed to withstand a
temperature of 50 0 C ambient.
iii) Enclosures
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
iv) Mast
v) Cab
Cab frame shall be fabricated from tubular steel and/or other structural
shapes enclosed with expanded metal or wire mesh. Cab floor shall be
of 6 mm thick Aluminum chequered plate or approved equivalent. Cab
door and landing level enclosure doors shall be electrically and
mechanically interlocked to prevent the cab from being operated unless
the cab door and landing level enclosure doors are fully closed and to
prevent the doors from being opened while the cab is in motion.
One cabin fan and two recessed fluorescent lamps along with the fittings
to be provided with one no. emergency light with battery & battery
charger.
vii) Buffers
Sufficient no. of buffers of spring loaded/hydraulic type shall be fitted
below the cab. The buffer shall be capable of stopping the cab without
permanent damage or deformation to themselves or any other part of
the equipment.
viii) Power Supply
Two in comers for the power supply to each elevator shall be provided
with cable key inter to check.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
(c) Electric and mechanical interlocks on cab access door and landing
level enclosure doors.
(d) An ultimate three phase over travel limit switch which cuts off power
and control supply in case of over travel. The switch can also be
manually turned to off position.
(f) An alarm push button shall be provided in the cage. Alarm signal will
be transferred to the auxiliary panel at elevator base. The auxiliary
panel will have battery and battery charger for the alarm horn.
Potential free contracts for remote alarm shall also be provided.
(g) Reverse phase relay connected to prevent operation of the cab with
improper phase rotation or failure in any phase in the power supply.
(h) The cable shall be supported by brackets on the cage and guide
rails. A cable trolley will keep it in tension and will be guided on the
same rail as the cage. The trailing cable shall run through cable
guides.
(i) One auxiliary panel shall be furnished and mounted on the ground
level enclosure. Panel shall be in enclosure equipped with a main
"ON-OFF" switch, main Contractor, relays, control transformer and
MCB's, terminal blocks, and all other accessories required for
normal operation of the elevator.
(j) One main control panel shall be furnished and mounted on the top
of cab. Panel shall be in enclosure equipped with necessary
equipment like rectifier, battery, battery charger, contactors,
breakers, control transformer and MCB's, thermal overload relays
and all other equipment and accessories required for normal
operation of the elevator.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
button, limit switches, and all other necessary control devices
required to ensure safe and continuous cab operation, Cable
guides shall be installed every 6 meters to avoid entanglement of
this cable.
(l) Each landing assembly shall include a limit switch and push button
control station installed and wired to a landing junction box.
x) Electric Motor
Elevator drive motor shall be squirrel-cage induction type designed and
manufactured to conform to the requirements of this specification.
Motor shall be totally enclosed and furnished with cast iron or Al alloy
frame, brackets, gaskets conduit box & fan cover. Motor shall be
furnished with grease pre lubricated, double-shielded, anti-friction
bearing having life rating of not less than 42,500 hours under coupled
service requirements. All exposed metal surfaces shall be protected with
a polyester paint or coating which is moisture & corrosion resistant.
Motor shall be provided with internal 220 Volt AC single-phase space
heaters or an alternate heating system to prevent condensation within
the motor during extended periods of idleness.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
xi) Cables
Insulated armoured power /control cable shall be FRLS - HR insulated,
stranded copper/ aluminum conductors and shall be provided in
accordance with IS: 1753 (latest edition) and IS: 1554 (Part-I) (latest
edition).
Trailing cables in the elevator shaft should be specially designed for the
specific service and shall conform to IS. Trailing cables shall be EPR
insulated for 1.1 kV and shall be neoprene jacketed flexible cord.
Conductor accessories including terminal materials like glands, lugs etc.
markers, tying materials, and cable supports shall be furnished and
installed.
xii) Earthing
c) The primary hydro cyclones shall be fitted directly above the belt
filters.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
b. Each belt filter shall have independent 2x100% vacuum pumps and
2x100% gypsum cake wash pumps.
d) A 2 m (min.) wide platform shall be provided around each belt filter for
easy approach & maintenance. Handling facilities for replacement of
heavy components of the belt shall also be provided.
e) The vacuum pumps shall be of low speed liquid ring type of proven
design. The design of the vacuum pumps shall avoid cavitations under
all operating conditions. The seals shall be of proven design.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
h) Each vacuum receiver tank(s) shall be provided with slide plate type
pneumatic vacuum breaker. The plate shall be stainless steel with a
min. thickness of 3 mm.
Water from vacuum receiver tank(s) and the secondary waste water
hydro cyclone underflow shall be taken to a common filtrate tank for
recirculation to the wet ball mill/ gypsum recovery system through 2 x
100% pumps. The pump shall be capable of pumping of filtrate water
with solid concentration of not less than 10%.
ii) Two (2) nos. Lime tanks each of minimum 2 m3 capacity shall be
provided for neutralization of waste water. The tanks shall be of carbon
steel construction with epoxy painting and shall be provided with SS
dissolving baskets, agitators of SS construction, drain, overflow and
dosing connections etc.
iii) The waste water tanks shall be of steel construction with epoxy painting
and shall be provided with agitator. 2x100% horizontal centrifugal pumps
shall be provided, along with requisite piping for pumping the waste
water to ash water sump. The material of Casing and impeller shall be
rubber lined Cast Iron (IS:210 Gr FG260). Shaft and Shaft Sleeves shall
be Stainless Steel-410.
The limestone to be used for FGD system shall be received and unloaded in
storage area of RCC with covered shed provided in the power plant. The
capacity of storage area shall be for 15 days limestone requirement of the
power plant. Limestone from storage area to the FGD area shall be
transported using trucks/ dumpers (by purchaser).
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
i) Hoppers &Chutes, flap gates and rack & pinion gates shall be furnished
integral with limestone handling system being supplied. All necessary
accessories, shall be provided to ensure proper flow/storage/bifurcation
of limestone as per system requirements.
ii) Two (2)) no. hoppers of adequate volumetric capacity shall be provided
to reclaim limestone with the help of trucks/ bulldozers. The hoppers
shall be provided with valley angle of 600 so as to avoid the jamming of
limestone.
iii) A grid of M.S. construction of adequate opening size shall also be
provided over this receiving hopper. The larger piece of limestone shall
be broken into small sizes over the grid and fed back to the hopper by
manual labour. This gird shall be designed to take the load of moving
loaded truck/ dumper.
iv) Transfer chutes shall be adequately sized and sloped to ensure smooth
flow of Lime without any accumulation anywhere. The minimum valley
angle of chutes shall be 60 degrees from horizontal.
v) Direct impact of material on conveyor belt shall be avoided by providing
an inclined surface at 60 degrees valley angle at the feeding point to
guide the material in direction of belt travel. Further, chute construction
below flap gate shaft shall such that there will not be any accumulation
of limestone dust between chute and gate in that zone.
vi) Hoppers and Chutes shall be made of minimum 10 mm thick
TISCRAL/MS or equivalent with adequate stiffeners. Long chutes
guiding flow from considerable height shall be provided with impact
plates wherever change in direction of flow takes place. Complete chute
work above the drive floor for conveyors provided with 'In-line magnetic
separators' shall be of 10 mm thick SS 304 in the zone of magnetic field.
viii) Bolted flange joints shall be of dust tight construction and necessary
sealing material shall be provided in all the flange connections for
adequate sealing.
i) Rotary actuator operated Rack & Pinion isolating gates underneath each
hopper shall be provided for controlling the flow of limestone to the
respective conveyors. The bidder shall ensure that the arrangement
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
provided shall control the flow within + 5%. The isolating gates shall be
fabricated from mild steel plate with liner plate of 10 mm thick TISCRAL
or equivalent material and shall be encased to the hopper by means of
bolts. The gates shall be operated by means of double rack and pinion.
The material for rack & pinion wheel shall be cast steel and shaft shall
be EN -B.
ii) The rack and pinion shall be operated by means of hand chain/motor
from the floor itself. Manual effort required to operate the rack and pinion
gate shell not exceed 35 kg.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
vi) Suitable arrangements shall be provided in the magnet for keeping the
coil of the magnet dry from atmospheric condensation when the
magnetic separator is not in use.
4.5.5 Vibrating Feeders
ii) The skirt plates shall be fitted with modular segmented and replaceable
rubber skirting pads having facility of adjusting the pressure on the belt
conveyor and shall have provision of on line removal for the purpose of
easy maintenance. All care shall be taken while designing, to combine
good sealing with minimum belt wear.
i) The motor operated two position flap gates shall be provided in transfer
chutes and shall be complete with electrically operated actuators. The
gates shall be of robust construction and suitable for trouble free
operation. The face of the flap gate shall be mode out of 10 mm thick
TISCRAL or equivalent material.
ii) The equipment shall be capable of being operated for at least 15
switchings per hour at rated load and thrust and shall be suitable for 10
Nos. consecutive switchings at rated load and thrust. The equipment
shall be shop tested to prove this requirement.
iv) The motor rating for the actuator shall be so selected as to provide
sufficient thrust for operation of the flop gates against the moving weight
of limestone and/or flap gate. The flap gate travel shall be in the range of
60 deg. to 70 deg. The motor shall be completely dust tight.
v) The flap gate shall be provided with 10mm thick TISCRAL liner plate or
equivalent material on both faces of main plate. The material of shaft shall
be EN-8 or equivalent.
vi) Suitable thrust dependent limit switches shall be provided in the actuator,
which shall trip off the actuator motor in case of excessive thrust due to
jamming of the gates during its travel in either direction. Provision for
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
The belt shall be of grade ‘B’ as per IS: 1891 latest edition. The tenderer
shall include in his tender sufficient length of belt to take care of
mechanised joints. The belt shall have enough edge cover anchorage
to resist wear. Both ends shall be prepared for full vulcanized plies and
all the joints shall be vulcanised type.
ii) Idlers
All the idlers shall be heavy duty suitable for continuous operation at high
capacity. The diameter of idles roll shall be minimum 152 mm for both
carrying and return side. All idlers shall run in taper roller bearings
enclosed in dust and moisture tight housing balanced and free to align
themselves in carrier brackets. Bearings shall be provided with grease
seals to protect them from dust and prevent loss of lubrication. All the
roller shall be smoothly finished to prevent wear on conveyor belts. The
lubricant arrangement for each set of rollers shall be such that it shall
enable lubrication to be done from one side of the idler assembly.
Rollers used for idlers shall be made of ERW steel tube with wall
thickness minimum 4mm. The rollers shall be mounted on EN-8 spindles
by means of ball bearings. The bearing shall be adequately sealed and
lubricated for life.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
The conveyor belts shall be supported by three roll of 350 troughing idlers
at a suitable spacing along with run of the belt and at closer spacing at
vertical bends. The idler spacing at vertical bends shall be about one
third of the normal troughing idler spacing. The return idlers shall be
placed at maximum suitable spacing. The troughing rollers and return
rollers shall be mounted on suitable Brackets. Each roller shall be
complete unit removable and inter changeable with other rollers.
Self aligning trough idlers with side guide rollers shall be provided for
training the belt to keep it centered. The idlers shall be located about 3
meters ahead of the head pulley and beyond this at an interval of about
15 meters.
Similarly, on return side of the belt, self aligning idlers with side guide
rollers of suitable design and shape to minimise belt contact and edge
wear shall be provided. One such idler shall be located about 3 meters
head of the tail pulley, to center the belt on the pulley before it enters the
conveying run and other self-aligning idlers shall be located at suitable
spacing.
v) Impact Idlers
The impact idlers shall have steel diameter of minimum 139mm and
rubber thickness of 25mm. The rim and web of each disc shall be made
of special resilient rubber to provide with greater shock absorbing
capacity. The discs shall be mounted on steel tubes located in place by
means of keys and cellars, spaced so that necessary deflection of the
rubber may occur without interference. Spacing of impact idlers shall not
be more than 500 mm.
All pulleys shall be of mild steel construction with hub and disc
conforming to IS:2062 (Tested Quality). The pulley shall be capable of
resisting fatigue failure in the members connecting the hub to the rim.
The pulley shaft shall be of adequate size to keep the deflection to the
minimum and avoid fatigue failure in the pulley. Pulley shaft of 150 mm
diameter and less shall be made of machined, hot rolled or turned and
ground cold finished carbon steel or EN-8. Pulley shaft larger than 150
mm in diameter shall be made of carbon steel forging. The pulleys shall
run in antifriction double row self-aligning roller bearing. The bearing
shall be assembled in dust proof plummer block housing of a split type
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
with labyrinth seal. Shaftings shall have to be keyed. For conveyors with
in line magnetic separator the head end of the pulleys shall have shell
and end disc made of non-magnetic stainless steel material.
The drive and other belt pulleys shall be of adequate diameter to suit the
type of belt, number of plies, weight of duct without causing fatigue in the
bond between plies of the belt. Each pulley shall be minimum 50 mm
wider than the belt it supports. The diameter of the pulleys shall not be
less than those specified in IS: 1891 of 1968. All drive pulleys shall be
provided with an approved vulcanized rubber lagging with grooves.
Rubber lagging shall be of minimum 6 mm thickness.
The sloping back of each transfer chute shall be spaced from the return
belt to permit use of a belt cleaning unit and arranged in such a way that
the dribbles shall be returned to the same chute i.e. handling the main
flow of material. The belt cleaner shall be of the rubber edge spring
loaded type. Pivots of the scraper arms shall be amply protected from
the dust and shall have reliable lubrication to ensure freedom from
sticking. The design and construction of the belt cleaner shall be such
as to ensure easy installation and maintenance.
ix) Take-Up Tensioning Gear
The take up and tensioning gears shall be sufficient to cope with the
anticipated elongation of the belts during service and to maintain the
necessary tension. All belt conveyor take-up pulley shall be of the gravity
type. The take- up pulley shall be supported on a sliding frame to permit
free movement to maintain constant tension of the belt wherever
required. The supply shall be complete with all pulleys, cables and
counterweights etc. All take up gears shall be provided with suitable
guard to the approval of the purchaser. Each belt feeder shall be
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
equipped at its tail and with a take-up arrangement that shall comprise
tail shaft unit mounted in 2 horizontal type screw take-up units. A total
adjustment of not less than 300 mm shall be provided in the screw take
up units. The provision for the adjustment of take-up bearings by means
of hand wheel or ratchet on the outer ends of the adjustment screws shall
be made. The take-up travel shall conform to BS:2890.
x) Hold Back Device and Brakes:
Automatic hold-back device of approved design shall be provided for
elevating belt conveyor. Hold-back shall prevent backward movement of
the loaded belt in the event of drive power failure. The hold-back device
shall be of the roller type of sufficient torque integral with reduction gear
unit. Electro-magnetic brakes of adequate capacity shall also be
provided in addition to the hold-back device.
i) The crushers shall be of hammer mill type for sizing the input limestone
feed size of (-) 250mm to (-) 20 mm size. Limestone feeding shall be
through vibrating screening feeder arrangement and shall be designed
based on following:
ii) The rotor shall consist of forged steel shaft with integral discs or key fitted
discs on shaft. Hammers shall be held by spring dowel bushes & shall
be arranged around the circumference of the rotor. The number of
hammers and number of rows shall be selected as per requirements.
iii) The grinding walls shall be arranged symmetrically around either side of
the rotor and carried by spindles supported in bearings attached to the
casing. The wall shall consist of grinding wall supports and wear
resistant grinding plates/lmpact plates bolted on. For product size
control, distance between the grinding plates and hammer shall be
adjustable.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
iv) The hammer shall be in two parts- head and arm. The hammer head
shall be of wear resistant steel material. The hammer arm shall be of
forged alloy steel. In the event of wear, only the hammer head shall be
replaced. Arms shall be selected so that they have long life and do not
require frequent replacement.
vi) The hammer crusher will be driven through electric motor, scoop type
hydraulic coupling and gear box.
i) The Bucket Elevator shall be sized to handle the design capacity with
the minimum material bulk density and a maximum bucket filling of 75%
& maximum material size, for continuous twenty-four hour service in a
heavy duty industrial application, handling abrasive materials in a dusty
environment.
ii) Casing of elevator shall be self supported and capable of supporting
head shaft, drive, and service platform. Head section is to be split and
equipped with handles or lifting lugs for easy removal. Access and
inspection doors are to be provided.
iii) Intermediate sections are to have a minimum plate thickness of 4 mm.
Boot section to be fabricated of minimum 6mm steel plate, with front and
rear access panels. A beam is to be provided in casing for servicing
internal gravity take-up. The beam may be located either in the boot
section or intermediate section as applicable.
iv) Size, capacity and type of buckets and appropriate reinforcement
necessary for the application shall be adequately sized. Pin holes shall
be provided in bottom of buckets for air relief.
v) Bucket elevator drive should be sized for either 100% bucket filling at
minimum material bulk density, or75% bucket filling @ maximum
material bulk density, whichever is greater.
vi) Inspection and Access Doors shall be loose-hinged type with quick-
opening jamb bar fasteners and gaskets enclosed and retained in the
door.
vii) A dust collecting vent in the head section and boot section shell be
furnished with drilled flanges.
4.5.11 Limestone Silo/ Bunker
Two nos. limestone storage silos/ bunkers each of 24 hours storage capacity
of both the units shall be provided and shall be complete with supporting steel
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
Two bunker outlet chutes shall be provided for feeding limestone from bunker
to the feeders. The size of the opening chute shall be sufficient to ensure
proper flow of the limestone. There shall be no reduction of section in the
bunker outlet chute from bunker to feeder. The inlet chute shall be provided
with suitable poke doors/holes in order to remove jamming/blockage. A
motorized bunker shut-off gate shall be provided at the inlet to each feeder.
All parts of the gate in contact with limestone shall be of stainless steel
construction. The shut-off gates and its actuator shall ensure 100% closing of
the gate even with ‘bunker full of limestone. Facility shall be provided to
open/close the bunker outlet gate, through actuator, from remote as well as
local. In addition, a hand wheel with proper access shall also be provided for
manual operation of the gate. The force at the rim of the hand wheel shall
not exceed 35 kg with bunker full of limestone. The facility shall be provided
for unloading the bunker, in case of exigency, through feeder, to a truck at
ground level, along with all necessary chutes and diversion chutes.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
ii) All integral auxiliaries of the mills like hydro-cyclones, separator tank with
agitator(s) & 2x100% mill circuit pumps shall be sized to meet the above
conditions
iii) The mill hydro-cyclone set shall have sufficient redundancy. A minimum
10% spare hydro-cyclone shall be provided in each set of hydro cyclone.
Mill hydrocyclone shall meet the requirements indicated elsewhere in the
specification.
iv) All parts of the mill including mill body, trunnion, hydro-cyclones, integral
pipes, mill circuit pumps and other parts in contact with limestone slurry
shall be provided with replaceable rubber wear liners. The wear liners or
wear parts shall have a minimum guaranteed wear life of not less than
8000 hrs without reversal of the liners. The guaranteed capacity and
fineness of the mill shall not be affected within the guaranteed life of the
mill wear parts.
v) The material of the balls shall be chosen to ensure that the balls do not
lose their original shape and to ensure minimum ball consumption. The
contractor shall also guarantee ball consumption per ton of limestone
throughput. The contractor shall furnish the minimum ball diameter below
which the balls shall be replaced.
vi) Facility shall be provided for on-load loading of steel balls to the mill.
vii) The ball mill shall be driven by a motor through a peripheral gear. An
auxiliary motor shall also be provided for inching of mills after trip and
during maintenance.
viii) The lube oil system shall have 100% stand-by arrangement for lube oil
pumps and oil coolers of each circuit with independent pump / cooler.
Wherever required duplex oil filters shall be provided.
ix) The mill auxiliaries like separator tanks, mill circuit pump, hydro-cyclones
and all connecting pipes handling limestone slurry shall have replaceable
rubber linings.
x) Oil used shall be fire resistant. Lubrication oil reservoir shall include
heater, vent fill and drain connections, and shall be integrally skid
mounted with the oil pumps.
xii) A mill cradle system shall be provided for each ball mill. One (1) portable
hydraulic jacking system including jacks, all necessary valves, gauges,
controls and flexible hoses shall be provided.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
a) The compressed conveying air shall be passed through these bag filters
to retain the Limestone particles in the silo.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
c) The bag filter shall be of automatic reverse pulse jet cleaning type using
jet of air to produce high-pressure wave, which remove the settled
limestone particles from fabric and discharge into the silo. Bidder shall
supply all accessories like orifice, pipe, solenoid valve, sequential timer
etc.
d) The bag filter must ensure adequate collection efficiency to achieve
maximum dust not exceeding 30 mg/m3 of air flow as per the norm.
e) The pressure drop across Bag filter should not excess 100mm of water
column.
g) The Bag filter cloth shall be of standard quality and bag filter shall be of
reverse pulse jet cleaning type.
h) Material of construction:
Casing : M.S. fabricated.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
The sump pumps shall pump out the drains in various areas of FGD system
and shall be provided at all locations where natural drainage is not possible.
The piping up to the nearest disposal point shall form part of the tenderer’s
scope of supply. 2x100% capacity pumps (minimum 50 m3/h) of adequate
ratig shall be provided for each drain sump. The pumps shall be provided with
5% margin in flow and 10% margin in head over duty requirement. Size of the
drain pit shall not be less than 2m x 2m x 1.8 (depth) m.
Each drain pump shall be provided with seal water arrangement to prevent
ingress of into seals. Necessary inter-locks to ensure that sump start only with
adequate seal water flow shall be provided. These pumps shall conform to
the following requirements:
v) Material of construction:
a) Casing/Bowl - Alloy C.I. (350 BHN)
(min. 2.7 % Ni, 1% Cr)
b) Impeller - Alloy C.I. (350 BHN)
(min. 2.7 % Ni, 1% Cr)
c) Shaft - Stainless steel
d) Base plate - M.S.
e) Gland packing - Clear water sealed bush.
fi) Shaft sleeve - Stainless steel
gi)Bearing - Cutless rubber in Bronze
i) General
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
The pumps shall be provided with 5% margin in flow and 10% margin in
head over duty requirement. The bidder shall furnish in the offer detailed
calculations justifying capacity and head of the pumps.
Pumps are required to operate for some period with discharge valve
closed. The pumps shall be suitable for zero-flow operation for a
reasonable period.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
vi) Casing
The casing shall be structurally sound to provide housing for the pump
assembly and shall be designed hydraulically to minimise radial loads at
part load operations. The casing shall be capable of withstanding a
hydrostatic test pressure equal to twice the pressure at rated capacity or
1.5 times shut-off head whichever is greater.
Pump casing may be axially or radially split or barrel type. The casing
shall be of robust construction. All liquid passages in the casing shall be
finished to smooth surfaces as far as possible. Casing drain and vent
connections with plugs and valves shall be provided where required.
Dowels shall be provided. Casing shall withstand without expansion joint
the usual moments and thrusts. The casing shall of cast steel. Pressure
casing (or outer casing) shall be generally in accordance with the
stipulation of API-610.
vii) Impeller
Impellers shall be made in one piece and securely fixed to the shaft.
Means shall be provided to prevent loosening during operation including
rotation in reverse direction. Impeller fastening nuts (if provided) shall
be of cap type and shall tighten in the direction of normal rotation. The
Impeller shall be of stainless steel. Replaceable type wearing rings shall
be provided at suitable location for each pump (where applicable). The
wearing rings shall be so fitted as to prevent turning while the pump is in
operation.
viii) Shaft
The shaft shall be adequately sized to withstand all stresses from rotor
weight and hydraulic loads etc. ground and polished to final dimensions.
The design of the shaft shall also take into consideration the critical
speed of the shaft which shall be at least 20 percent above the maximum
operating speed.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
x) Bearings
The design of oil lubricated bearings shall be such that the bearing
lubricating oil does not contaminate the liquid being pumped. Grease
lubricated ball bearings are acceptable, if the pump is specifically
designed for grease lubrication and if shaft speed is less than the speed
limit recommended by the bearing manufacturer and the fluid
temperature does not exceed 65.5oC (1500F). Each bearing housing
shall have drain plug.
The Bidder shall provide the necessary piping, valves, boosters, fitting
etc. for the gland sealing connection. For mechanical seals, the mating
surfaces shall be suitably hard faced to ensure long life.
xiii) Coupling
The pump & motor shaft shall be connected with a suitably designed
flexible coupling of approved design preferably with a spacer to facilitate
dismantling of the pump without disturbing the motor. Necessary
expanded metal coupling guards for the coupling shall also be furnished.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
For limestone slurry handling pumps and where fast wearing of pumps
is likely due to the particular service conditions, variable speed drive shall
be employed, thus enabling operation of pumps at 100-200 rpm over-
speed compared to the impeller speed corresponding to the rated
operating point. Pumps shall be suitable for operation at such higher
speeds. When variable speed drive as above is provided, it should also
be possible to operate the pumps at 50-100 rpm under-speed.
For pumps coupled to motor with the variable speed drive transmission
system, separate base plates for pumps & motors are acceptable.
xvi) Accessories
The following accessories shall be supplied by Bidder for all pump motor
sets:
a) Foundation bolts and nuts for pump, motor and base plate.
b) Transmission guard for flexible coupling/V-belt transmission etc. as
applicable.
c) Slide rails for motors if variable-pitch belt drive is provided.
d) Pump pulley, motor pulley (variable pitch), set of V- belts or flexible
coupling, as applicable.
e) Suitable connections for sealing/cooling/flushing water supply, if
applicable.
f) Lubrication fittings as necessary for proper and easy lubrication of
the equipment.
g) Drain and vent cocks as required.
h) Priming funnel or overhead tank, as required.
i) Anchor bolts, sleeves, inserts, lifting lugs, eye bolts etc.
j) Any other accessories mentioned elsewhere in this specification.
xvii) Drive Motors
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
ii) All paints & paint material used shall be procured from approved
manufacturers. Paint shall be supplied in manufacturers original containers
with the description of content, specification No., colour, ref no, date of
manufacture, shelf life expiry date & pot life.
iii) The paint manufacturers shall provide coating system data sheet for each
coating system to be used containing the information on surface
preparations, film thickness, recoating intervals, mixing ratio, thinner details
and coating repair systems.
iv) In general Shop fabricated equipment will be delivered to the site coated
with a shop applied system or the manufacturer's standard finish in
accordance with the requirements of this specification. For equipment that
has received shop prime coat, touch-up prime coat and additional coats
shall be applied in accordance with the coating schedule.
v) Preparation of Surfaces
a) All surfaces to be painted shall be thoroughly cleaned of all grease, oil,
loose mill scale, dust, rust, weld spatters, sharp edges and any other
foreign matter. Removal of grease and oil contamination shall be in
accordance with SSPC-SPI prior to cleaning process.
b) Mechanical cleaning by power tool and scrapping with steel wire brushes
shall be adopted to clear the surfaces. However, in certain locations
where power tool cleaning cannot be carried out, hand scrapping may
be permitted with steel wire brushes and/or abrasive paper.
vi) Mechanical /power tool cleaning shall be done as per grade St-2 or St-3,
of ISO 8504-3.
vii) Blast Cleaning:
a) Compressed air supply for blast cleaning shall be free of water and oil.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
b) Abrasives used for blast cleaning carbon steel and alloy steel shall be
as per ISO 8504-2 and SSPC painting manual. Suggested abrasives
may be chilled iron grit or shot steel and malleable iron grit and shots
nonmetallic abrasive (aluminum oxide, copper slag, garnet etc.).
c) Surfaces to be coated shall be free of all grease, oil, loose rust, and
loose mill scale. Oil and grease shall be removed by solvent cleaning
method as outlined in SSPC - SP - 1 prior to blasting.
d) Surfaces prepared for coating shall be coated the same day and before
any visible rusting occurs (the time elapsed between blast cleaning
and commencement of painting shall under no circumstances exceed
4 hours, but in any case must commence before signs of degradation
occur).
c) Paints shall not be applied within 50 mm of edges which will later have
to be welded. Such weld areas shall be taped/one coat of weldable
primer for distance of 50 mm either side of the weld line.
ix) The following coating inspection & test shall be carried out:
a) Dry Film Thickness as per ISO 2808 No.6.
b) Holiday Test as per ASTM D 5162/ NACE RP 0188.
c) Adhesion Test as per ISO 2409 for cross-cut test, or a pull-off test as
per ISO 4624/ ASTM D 4541.
x) Underground piping shall be given protective coating as per latest edition
of relevant codes. The pipelines routed in the corrosive area shall be
provided with rubber lining on the external surface. In addition, all steel
parts of the plant which are wetted or submerged in water and all structural
members shall be given protective coating.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
iii) The speed of the fan shall not exceed 960 rpm for fan with impeller
diameter above 450 mm and 1440 rpm for fan with impeller diameter 450
mm and less. The first critical speed of rotating assembly shall be at least
25% above operating speed.
iv) The control room of FGD system shall be air conditioned. The system
shall consist of adequate number of package air conditioners (PACs)
with 100% standby arrangement. PAC units shall be provided as
required. PAC units shall be factory tested and assembled self-
contained units complete with refrigerant compressor, coils, fans,
insulation and wiring. Various parts of PAC units wherever required shall
be insulated with expanded polyethylene conforming to IS:4671. The
PAC unit shall comprise of an evaporator (indoor air) blower section and
an air cooled condenser (outdoor air) section. Heavy gauge steel
cabinet finished with paint of approved color, shall be used to house
components of PAC. The evaporator and condenser coils shall be
arranged for direct expansion cooling and shall be formed of aluminum
fins mechanically bonded to seamless copper tubes and electrically
tinned. The inter-connecting refrigerant circuits shall comprise of
hermetically sealed scroll compressor and motor with all necessary
isolation valves, with adjustable set point, sight glass, copper tubing and
pipeline ancillaries. The condenser coils shall be air cooled by propeller
type fans complete with safety guards. The condensing coils shall be
suitably arranged to avoid radiant heat pickup from solar sources.
v) All Gl sheet metal ductwork required for ventilation and air conditioning
system shall be furnished by the supplier. All ducts and plenums shall
be constructed out of standard quality galvanised steel sheet. All sheet
metal ducts shall be fabricated and installed in conformity to the
requirements of IS:655. Steel supports for the ductwork shall be
furnished as required. The thickness of ducting steel shall be 1 mm min.
For ducting with large size exceeding 1300 mm it shall be 1.25 mm. The
flexible connection between fan and ducting shall be on Teflon
impregnated canvas. The zinc coating on Gl sheet shall be 275 gm/m 2
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 4 (Mechanical works)
vi) The other areas of the plant, limestone slurry pump house and limestone
recirculation pump house adjacent to limestone absorber, toilets etc.
shall be provided with mechanical exhaust system, using wall mounted
exhaust fans. The exhaust fans shall be horizontal, wall mounted, direct
drive type with low noise and minimum vibrations. The impellers shall
be of aluminum cast in single piece and dynamically balanced. The fans
shall be complete with suitable supporting/mounting brackets, frames
nuts, bolts, gravity louver damper, brackets in inlet screen and vibration
isolators etc.
i) Slurry pipes shall be designed to keep the velocity above the settling
velocity under all operating conditions. The contractor may provide a
recirculation line with motorized isolation valve for the above purpose.
ii) All the pipes handling slurry shall be provided with replaceable rubber
lining of proven quality. The Contractor can provide slurry pipes of size
lower than 3" made up of FRP material if it has previous experience of
providing the same.
iv) The isolation valves for slurry applications shall be of knife gate/ butterfly
type with rubber seats designed to prevent accumulation of solids on the
valve seat.
v) Bidder shall provide all necessary arrangements for purging & flushing
of all the process pipelines, equipment etc.
vii) All pipes, valves, rubber expansion joints and fittings coming in contact
with corrosive fluids shall be made of, or suitably lined with material
capable of satisfactorily withstanding the effects of such fluids. All the
sampling valves shall be of PVC diaphragm/ rubber lined. The butterfly
valves shall conform to ANSI/ AWWA C504-80/ BS 5155 or equivalent.
The NRVs shall conform to BS 1868 or equivalent. The rubber expansion
joints shall conform to relevant Indian standards or equivalent.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 4 (Mechanical works)
viii) The pipelines carrying water, air etc. should be sized on the following
allowable velocities:
e) Compressed air : 5 - 10 8 - 12 10 - 15
2 kg/cm2g and up.
ix) The over ground pipes shall be suitably laid on proper supports to
prevent sagging in any section. Pipe racks shall be provided for over
ground crossing of the pipes over the road sections. For underground
crossing below the roads, suitable RCC culvert or heavy duty hume pipes
shall be provided. All pipe bends shall be provided with suitable anchors.
x) The valve pits of adequate sizes shall be provided for housing the valves
on underground piping. The valve pits shall be properly covered from
the top to prevent ingress of rain water into the pits. Suitable rung
ladders/stairs shall be provided for entry into the pits.
xi) Pump suction velocity for water should be restricted to maximum 1.5 m/s.
Pump discharge velocity for water should be restricted to maximum 2.5
m/s. Velocity in water drain shall be kept as 1m/s. All piping handling raw
water/ clarified water/ DM water shall be designed for a pressure not less
than the shut-off head of the pumps of the respective system.
xii) The fittings shall be constructed of materials equivalent to the pipe with
they are used.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
c) Forged Steel Fittings: Forged steel fittings shall be used for socket-
weld and steel threaded connections and shall conform to ANSI B
16.11.
d) The minimum class rating of socket shall be 2000 lbs for threaded
fittings and 3000 lbs for socket welded fittings.
e) Lined pipe Fittings: Fittings used with lined pipe shall be lined with the
same material as the pipe with which they are used.
xiii) Flanges
a) Flanges shall be constructed of materials equivalent to the pipe with
which they are used.
b) Steel flanges shall conform to AWWA C207/ ANSI B16.5/ ASME
B16.47, 150 #.
c) Steel flanges 65 mm and larger shall be of the weld neck or slip-on
type; and all steel flanges 50mm and smaller shall be of the socket
type. Slip-on flanges shall generally be used only when the use of
weld neck flanges is impractical. Steel flanges shall have raised face
flange preparation. Flat face flanges shall be used to mate with
nonferrous flanges.
d) Carbon steel flanges shall be of ASTM A105 material.
xiv) Expansion joints shall be of spool type with right angle full-faced flanges
of reinforced rubber and fabric with metal retaining rings.
xv) Valves
a) Valve bodies shall generally be constructed of materials equivalent to
the pipe with which they are used. Valve body and trim materials of
construction shall be in accordance with applicable ASTM and AISI
standards.
c) Steel body gate. Globe, angle, and check valves shall be designed
and constructed in accordance with ANSI B16.34 as applicable. Valve
bodies and bonnets shall be designed to support the valve operators
(Hand wheel, gear, or motor) with the valve in any position, without
external support.
d) Steel body valves 50 mm and smaller shall have forged steel bodies.
All valves, except gate valves, shall have seats of the integral type.
Gate valves shall have renewable seats. Valve ends shall be socket-
weld type unless otherwise required.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
f) Steel body valves 65 mm and larger shall have cast steel bodies. The
face-to-face and end-to-end dimensions shall conform to ANSI
B16.10. Bonnet joints shall be of the bolted flanged type having flat
face flange facings for Class 150 valves; and male and female facings
for Class 300 and 400 valves. Body ends shall be butt weld type
unless otherwise required.
h) Iron body gate, globe, and check valves shall have cast iron bodies
with bronze trim. The face-to-face dimensions shall be in accordance
with ANSI B16.10. These valves shall have flanged bonnet joints.
Gate and globe valves shall be of the outside screw and yoke
construction. Body seats shall be of the renewable type. Gate valves
shall be of the wedge disk type. Lined cast iron body diaphragm and
check valves used with lined piping shall be flanged body with liner
and diaphragm material suitable for the service.
j) Butterfly valves shall generally be used for size 150 mm and above for
cold water services only. Butterfly valves for buried service shall be of
cast iron body material and shall be equipped with flanged ends.
k) Cast iron butterfly valves shall have pressure class selected based on
the piping design pressure as follows:
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
l) Butterfly valves for other than buried services shall be of carbon steel
or cast iron body material depending on the service application.
Valves 600 mm and larger in size shall be equipped with flanged ends.
Valves 500 mm and smaller in size shall be of the wafer type, or lug
wafer type, if used with steel piping:
n) Bronze gate and globe valves 50 mm and smaller shall have union
bonnet joints and screwed ends. Gate valves shall be inside screw,
rising stem type with solid wedge disks. Globe valves shall have
renewable seats and disks.
o) Bronze valves 65 mm and larger shall have bolted flange bonnet joints
and flanged ends. Gate and globe valves shall be of the outside
screws rising stem construction. Gate valves shall have either integral
or renewable seats. Globe valves shall have renewable seats.
All equipment and ducts starting from tap off on outlet duct of the ID fans
to inlet of new chimney, wet flue(s), bypass duct to existing chimney shall
be protected for conservation of heat energy from loss to atmosphere,
as required.
ii) The insulating material to be used shall be Lightly Bonded Rock Wool
insulation material of density 100 kg/m3 as per IS:8183 “Specification for
Bonded Mineral Wool”. The thickness of insulation shall be such as to
keep the loss of heat to the minimum/ economical and to limit the surface
temperature to 60oC.
iv) The hot surfaces where the heat loss is inconsequential but are within a
distance of less than 2 m from floor or walkways shall be applied with
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
vii) Binding and lacing wires shall be 20 SWG galvanised Steel wire and
screws shall be of galvanized steel, check headed, self- tapping type.
viii) Hexagonal wire mesh netting shall be 10-13 mm aperture and at least
0.71mm diameter galvanized steel wire.
ix) All Straps and bands shall be Galvanized Steel. Bands shall be 20 mm
wide and 0.6 mm thick. For securing Aluminum sheathing material,
stainless steel or anodized aluminum bends shall be used.
xi) Suitable lugs and spacer rings shall be provided to support the insulation
and cladding. Heat conduction through these lugs and rings shall also
be suitably checked.
i) Two (2) x 100% capacity Indoor, with minimum operating pressure of 8.0
kg/cm² (g), AC motor driven multi-stage, oil free, package type rotary
screw air compressors shall be provided. Each compressor shall consist
of two (2) compressor elements, flanged to a step up gear box with
integrated oil sump, oil and water piping, intercoolers, after coolers,
pulsation dampers, moisture separators, discharge silencers etc.
ii) Compressors and all its accessories such as intercooler, after cooler,
motor control panel with starter, refrigerated air dryer shall be mounted
on a common skid and shall be complete with air, water and drain piping
and power and control cabling within the skid limits such that it becomes
ready to start commissioning of compressed air package requiring no
foundation. This complete skid shall be mounted on a set of anti-
vibration mounting pads and shall have a facility for lifting.
iii) Intake Air Filter-cum-silencer
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
Horizontal shell and tube type, water cooled cooler (inter and after)
having tubes fixed on tube sheet fixed in a seamless Cast Iron shell shall
be provided.
v) Air receiver
Each compressor shall be provided with an Air Receiver. The air receiver
shall be vertical, cylindrical steel plate fabricated of 10 m³ capacity with
tori spherical/ elliptical dished end construction along with all required
accessories such as safety relief valves, pressure gauges, pressure
switches, automatic drain trap connections. The design of air receiver
shall be as per IS:2825-class II.
i) Complete firefighting system for all areas viz. absorber, lime handling
and preparation, gypsum dewatering/ handling and control room etc.
covered under FGD plant shall be provided. Firefighting system for FGD
plant shall be provided as per NFPA, USA regulations. All equipment
such as flow control valves, nozzles, projectors, fire detectors etc. shall
be Underwriters Laboratory/Factory Manual approved. The provisions in
the latest revisions of Indian standards shall be applicable to equipment/
services of the system. All equipment such as pipes, valves, fire
extinguishers, cables etc. should be ISI marked.
ii) Firefighting system shall comprise of water hydrant system for FGD plant
area. The hydrant system shall be complete with hydrants, hose pipes
with instantaneous couplings, branch pipes with nozzles and hose
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 4 (Mechanical works)
cabinets etc. The water for hydrant/ spray system for FGD plants shall
be suitably tapped from the existing hydrant/ spray headers of the power
plant.
iii) Adequate number of portable fire extinguishers of carbon dioxide, DCP
& foam type (as applicable) shall be provided for all buildings and pump
houses of plant including MCC & Control rooms. Adequate number of
mobile fire extinguishers of carbon dioxide and DCP type shall also be
provided. Fire detection & alarm system including call points shall be
provided for all buildings & complete area of FGD system.
iv) The fire detection, protection and alarm system shall be suitably
interfaced/ integrated with the existing firefighting system.
vi) Fire detectors of requisite types such as smoke detectors (ionization and
photoelectric type) shall be provided. The coverage area of fire detectors
shall be 20-25 m2/ detector for air conditioned control rooms and 35-45
m2/ detector for other areas. All detectors shall have LED indicators
showing ‘Normal’ and ‘Operated’ status. The manual call points shall be
provided at convenient points such as entrance to rooms, near staircase,
passage etc.
Hangers and supports shall be capable of carrying the sum of all concurrently
acting loads. They shall be designed to provide the required supporting
effects and allow pipe line movements as necessary. The bidder shall provide
all guides, anchors, braces, dampeners, expansion joints and structural steel
to be attached to the civil works and foundations.
For the normal operation and transfer of equipment to maintenance area with
in the building and/ or to transfer the equipment outside the building up to
ground floor for further transportation, necessary hoist complete with trolleys
and chain-pulley blocks and monorails shall be provided at suitable locations.
The tenderer shall indicate the brief description, location and capacity of such
hoist in his tender drawings.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
b) Hoist cable, hoisting block and hooks, with maximum hoisting speed
6m/min, complete with drive moto.
c) Limit switches to prevent over hoisting, over lowering and over
travel.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
vii) For electric hoists, trolley movement and hoisting shall be effected by
using two separate motors.
viii) An electromechanical brake shall be provided for hoisting as well as
cross travel. Brake lining shall be of asbestos.
a) Condensation calculations.
b) Minimum 1:12 scale physical flow model for liquid collector
design.
c) Computational flow model for plume downwash analysis.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
All structural and auxiliary steel works covered under the mechanical scope of
supply, shall be designed and installed in accordance with the latest applicable
code of Indian Standards with regard to earthquake and wind load. While
designing the structures, adequate allowance for the maintenance loads shall
also be taken into consideration in addition to the equipment loads and live load
of 500 kg/sq.m. Structural steel works shall be carried out as specified in the
civil and structural works of this specification. Cathodic protection shall be
provided for all structural steel works due to very corrosive and saline
environment at the plant site.
Complete FGD system for both the units including common auxiliaries shall be
controlled from FGD control room. Provision for Operation and control of
complete FGD from main plant central control room shall also be provided.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
ii) PLC with redundant (2x100%) controllers shall be provided and FGD
control system shall be capable of ensuring safe and reliable operation
during all regimes of operation i.e. start up, normal operation as well as
in emergency situations. The PLC shall have a communication interface
link from the FGD control system to the existing Main Plant Control
system for status/information exchange. However, for control purposes
hardwired interconnections shall be provided between existing Main
Plant control system and FGD control system. Normal mode of operation
in FGD plant control room shall be through CRT/keyboards during all
regimes of operation.
iii) All the required logic and interlocks shall be provided for safe and reliable
operation of FGD system. Same shall include but not limited to the
following:
Clear path’ permissive for starting of ID fans i.e. either FGD bypass
damper is open or the FGD system is in operation (all dampers in
FGD path open and limestone slurry system, booster fans on).
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
4.23.1 The following information/ technical data/ drawings shall be furnished by the
bidder along with his bid:
a) Process Description
b) System Specification
c) P & I diagrams.
d) FGD layout drawing
e) Equipment layout drawings.
f) Pump characteristic curves.
g) Fan/blower/compressor characteristic curves
h) Technical literature of the equipment.
i) Design calculations for FGD process, mass balance calculation & sizing
of various equipment of FGD plant.
j) Technical particulars of equipment as per bidding schedules.
Any other data required for proper appraisal of the equipment being offered
shall also be furnished if asked for by the purchaser or purchaser’s
consultants.
4.23.2 The following drawings/technical data shall be furnished after award of
contract:
i) All drawings/technical data mentioned at Cl. 3.5.1 above.
ii) Flow Schematics of entire plant including complete mass flow balances
and operating/design parameters for all media
iii) Startup& shut down diagrams
iv) Detailed drawing of connections with existing equipment
v) Control & Interlock write-ups.
vi) PG Test procedures.
vii) Valve schedules
viii) Motor schedules
ix) Process Water Balance.
x) G.A. drawings of all equipment.
xi) Data Sheet for equipment.
xii) General assembly plan and elevation drawings including ducts and
piping layout drawings.
xiii) Cross sectional drawings of major equipment of the FGD system
xiv) Fabrication drawings of equipment.
xv) Drawings indicating drains, cables channels, various cross overs of
above.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
All codes and standards referred below shall be understood to be the latest
version on the date of offer made by the bidder unless otherwise indicated.
Nothing in this specification shall be construed to relieve the vendor of this
responsibility.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 4 (Mechanical works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 5 (Electrical Works)
SECTION 5.0
ELECTRICAL WORKS
All 11kV, 6.6kV and 3.3kV switchgears shall meet the following requirements:
The equipment, materials and service shall conform to the latest applicable provision
of the following standards :
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 5 (Electrical Works)
5.1.2 Technical Parameters
i) The switchgears shall be indoor, metal clad, draw out type. The feeders rated
2000kW and above shall be provided with vacuum/ SF6 circuit breakers.
However, the motor feeders below 2000kW rating shall have vacuum/ SF6
contactors backed up by HRC. The operating mechanism of the circuit breakers
shall be of the stored energy type DC motor operated charging springs.
ii) The circuit breaker, contactor and switchgear assemblies shall have the
following technical parameters :
a) System parameters
b) Busbars
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 5 (Electrical Works)
2) Cable entry
- Power cables Bottom
- Control cables Bottom
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 5 (Electrical Works)
3) Accuracy class
Measurement core for
energy accounting and
audit meters
- on incomer of each 11kV, 0.2S
6.6kV and 3.3kV
switchgear
- on all 11kV, 6.6kV and
0.2S
3.3kV motor
Protection core
- differential and core PS
balance CTs
- other protection CTs 5P20
4) Minimum primary earth fault 3A
current to be detected by
core balance CT
h) Voltage Transformers
1) Rated voltage factor 1.2 continuous for all VTs, and 1.9 for
30 sec. for star connected VTs.
2) Measurement 0.2S
3) Protection 3P
4) VA burden Adequate for application
i) Fuses
j) Surge arresters
11 kV 6.6kV 3.3kV
1) Nominal discharge 500 Amp
current (8x20 micro-sec.)
2) Maximum system voltage 12 kV 7.2kV 3.6kV
3) Maximum standard impulse 25 kV (without any positive tolerance)
spark over voltage (peak)
4) Residual voltage at nominal 25 kV 12kV 8kV
discharge current
5) Temporary over voltage
capability (rms)
k) Contactors
134
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 5 (Electrical Works)
1) Current transducers
5.1.3 Metering
Ammeters with Ammeter selector switch to be provided on incomers, Bus coupler and
out going feeders. Voltmeters with voltage selector switch for each bus section to be
provided on bus coupler. On incomer panels of HT switchgear, energy meters (0.5
accuracy class) shall be provided. Transducers shall be provided to transfer the data
of current / voltage / power to DCS / PLC.
The energy meters shall be provided as per the Central Electricity Authority
(Installation and Operation of Meters) Regulations,2006 and its amendments.
However, the following energy accounting and audit meters shall be provided in
general :
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 5 (Electrical Works)
Energy accounting and audit meters shall be of accuracy class of 0.2S. The accuracy
class of CTs and VTs shall not be inferior to that of associated meters. In case,
numerical relays having built-in features of energy measurement of requisite
accuracy are provided in switchgear, separate energy meter is not necessary.
i) Switchgear panel
a) Each 3.3kV switchboard shall have two sections each of 100% capacity
and connected through a ‘Normally Open’ bus-coupler. These two
sections shall be fed from two independent sources to be arranged by the
bidder.
b) Single phase VTs on the incoming breaker panels shall be provided for
checking the voltage on both of the sections while paralleling. The
Automatic Reserve Closure (ARC) facility shall be provided on bus-
coupler breaker such that it will close automatically in case of failure of
any one incomer.
g) The trucks shall have distinct Service, Test and Isolated positions. It shall
be possible to close the breaker/contactor compartment door in Isolated
position also, so that the switchgear retains its specified degree of
protection. While switchboard designs with doors for breaker/contactor
compartments would be preferred, standard designs of reputed
switchgear manufacturer's where the truck front serves as the
compartment cover may also be considered, provided the breaker/
contactor compartment is completely sealed from all other compartments
and retains the IP-4X degree of protection in the Isolated position.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 5 (Electrical Works)
i) The VT/ relay compartments shall have degree of protection not less than
IP:52 in accordance with IS/IEC 60947. However, remaining
compartments can have a degree of protection of IP: 4X. No
louvers/opening shall be provided on the top of the panel. All other
louvers if provided, shall have very fine brass or GI mesh screen. Tight
fitting gourmet/gaskets are to be provided at all openings in relay
compartment.
j) Enclosure shall be constructed with rolled steel sections and cold rolled
steel sheets of at least 2.0 mm thickness, Gland plates shall be 2.5 mm
thick made out of hot rolled or cold rolled steel sheets and for
nonmagnetic material it shall be 3.0 mm.
k) The switchgear shall be cooled by natural air flow and forced cooling shall
not be accepted.
l) Total height of the switchgear panels shall not exceed 2600 mm. The
height of switches, push buttons and other hand operated devices shall
not exceed 1800 mm and shall not be less than 700 mm.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 5 (Electrical Works)
mechanism. Surge arrestor shall be provided for each motor/ transformer
feeder.
b) Circuit breaker shall be restrike free, stored energy operated and trip free
type. Motor wound closing spring charging shall only be acceptable. An
anti-pumping relay shall be provided for each breaker, even if it has built-
in mechanical anti-pumping features.
c) Plug and socket isolating Contacts for main power circuit shall be silver
plated, of self-aligning type, of robust design and capable of withstanding
the specified short circuit currents. They shall preferably be shrouded with
an insulating material. Plug and socket contacts for auxiliary circuits shall
also be silver plated, sturdy and of self-aligning type having a high degree
of reliability. Thickness of silver plating shall not be less than 10 microns.
iii) Protection
The protective Numerical relays shall be provided for protection of all the three
phases of feeders. Adequate electrical protections with auxiliary relays and
timers as required shall be provided for all the equipment which shall include
but not limited to following.
a. The 11/6.6/3.3 kV Incoming (Main & Bus Coupler) and Outgoing supply
feeders :
i) Three Phase Over current (50).
ii) Bus No-volt
iii) Lockout (86)
iv) Earth fault protection (50N)
v) Synchronizing check (25)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 5 (Electrical Works)
iv) Relays
a) The protective relays shall be numerical type. All relays, auxiliary relays
and devices shall be of reputed make and types proven for the application
and shall be subject to purchaser approval. The relays and timers shall
have appropriate setting ranges, accuracy, resetting ratio, transient over-
reach and other characteristics to provide required sensitivity to the
satisfaction of the owner.
c) Relays shall be flush mounted on the front with connections at the rear.
Provision shall be made for easy isolation of trip circuits for testing and
maintenance.
d) Relays shall be provided with self-reset contacts except the trip, lockout
relays and interlocking (contact multiplication) relays which shall be
manual reset type
h) All relays shall have hand-reset flags or other means for ready visual
indication of their operation and also of the faulty phase.
v) Contactor
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 5 (Electrical Works)
The surge arrestors shall be provided for all motor/ transformer feeders and
shall be metal oxide, gapped or gap less type generally in accordance with IEC
60099-1 and suitable for indoor duty. These shall be mounted within the
switchgear cubicle between line and earth, preferably in the cable
compartment. Surge arrestor selected shall be suitable for non-effectively
earthed system and rating shall be in such a way that the value of steep fronted
switching over voltage generated at the switchgear terminals shall be limited to
the requirements of switchgear.
f) Six (6) normally open (NO) and six (6) normally closed (NC) auxiliary
contacts shall be provided in Incomer, Bus coupler and tie feeders for
future use. For all other breakers/ contactor modules four (4) NO and four
(4) NC contacts shall be provided. The above contacts shall be wired out
to the terminal blocks. Contact multiplication, if necessary to meet the
above contact requirement, shall be done through electrical reset latch
relay.
a) All bus bar and jumper connections shall be of high conductivity aluminum
alloy. They shall be adequately supported on insulators to withstand
electrical and mechanical stresses due to specified short circuit currents.
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colour coded. .All horizontal & vertical bus bars shall have high voltage
sleeving.
b) The temperature rise of the horizontal and vertical bus bars when carrying
the rated current shall be in no case exceed 550C for silver plated joints
and 400C for all other type of joints. The temperature rise at the
switchgear terminals intended for external cable termination shall not
exceed 400C. Further the switchgear parts handled by the operator shall
not exceed a rise of 50C. The temperature rise of the accessible parts/
external enclosure expected to be touched in normal operation shall not
exceed 200C.
b) The earth bus shall have sufficient cross section to carry the momentary
short circuit and short time fault currents to earth as indicated under
switchgear parameters without exceeding the allowable temperature rise.
c) All joint splices to the earth bus shall be made through at least two bolts
and taps by proper lug and bolt connection.
d) The truck and breaker / contactor frame shall get earthed while the truck
is being inserted in the panel and positive earthing of the truck and
breaker / contactor frame shall be maintained in all positions i.e. Service,
Test and Isolated as well as throughout the intermediate travel. The truck
shall also get and remain earthed when the control plug is connected
irrespective of its position.
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front of the switchgear panel. These switches shall have facility for padlocking
in the earthed condition.
- Closing of the earth switch on a live connection. Three (3) nos. voltage
capacitive dividers shall be provided on each phase of the section
intended for earthing and three (3) nos. "RED" neon lamps/ LEDs
connected to these on the panel front for visual indication.
i) The earthing device (truck/ switch) shall have the short circuit withstand
capability equal to that of associated switchgear panel. 4 NO+4 NC of
auxiliary contacts of the earthing device shall be provided for interlocking
purpose.
x) Painting
All sheet steel work shall be pretreated, in tanks, in accordance with IS:6005.
Degreasing shall be done by alkaline cleaning. Rust and scales shall be
removed by pickling with acid. After pickling, the parts shall be washed in
running water. Then these shall be rinsed in slightly alkaline hot water and
dried. The phosphate coating shall be "Class-C " as specified in IS : 6005. The
phosphated surfaces shall be rinsed and passivated prior to application of
stoved lead oxide primer coating. After primer application, Electrostatic
Powder Painting shall be used. Finishing paint shade for complete panels
excluding end covers shall be RAL9002 and RAL5012 for extreme end covers
of all switchgears. The paint thickness shall not be less than 50 microns.
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d) All voltage transformers shall have suitable HRC current limiting fuses on
both primary and secondary sides. Primary fuses shall be mounted on
the withdrawable portion. Replacement of the primary fuses shall be
possible with VT truck in Isolated position.
Transducers shall be tested as per IEC – 600298 or impulse test etc. and
short circuit withstand capability as per ANSI C 37.90a, 1989.
a) Control and selector switches shall be of heavy duty, rotary type with
escutcheon plates clearly marked to show the positions. The switches
shall be of sturdy construction suitable for mounting on panel front.
Switches with shrouding of live parts and sealing of contacts against dust
ingress shall be preferred.
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b) On-Off control switches shall have three positions and shall be spring
return to 'Neutral' from close and trip positions. They shall have two
contacts closing in close position and two contacts closing in trip
positions, and shall have Pistol Grip handles. Lost motion feature shall be
provided wherever required.
c) Selector switch shall have two stay put positions as per the module
requirements indicated elsewhere. They shall have two contacts for each
of the positions and shall have black Spade handle.
a) Indicating lamps shall be of the panel mounting, LED type and low watt
consumption preferably built in the lamp assembly. The lamps shall have
escutcheon plates marked with its function, wherever necessary.
Red Closed
Green Open
White Auto-trip
Blue For all healthy conditions (e.g. control supply, spring
charged, and lock out relay coil healthy)
Amber For all alarm conditions (e.g. pressure low, over load)
also for Service and Test positions indications.
a) Each switchboard shall be provided with two (2) Nos. of 220 V DC feeders
for the control supply.
b) Under voltage relay to monitor each of the control supply shall be provided.
c) All DC circuits shall be fused on both poles. Single phase AC circuits shall
have fuses on line and link on neutral.
b) For motor space heater supply, one breaker / contactor normally closed (NC)
auxiliary contact of each motor feeder shall be wired out in series of switch
fuse up to terminals block in the respective panels of switch boards. The
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motor space heater supply shall be taken from Panel space heater supply
given to switch board.
a) Terminal blocks shall be 650 Volts grade, 10 Amps rated, one piece
moulded complete with insulating barriers. clip on type terminals, washers,
nuts and identification strips.
b) Terminal blocks for CT and VT secondary leads shall be provided with links
to facilitate testing, isolation star/delta formation and earthing. Terminal
blocks for CT secondary shall have the short circuiting facility.
b) A minimum clearance of about 600 mm shall be kept between the cable lug
bottom ends and gland plates for stress cone formation for XLPE cables.
Interphase clearance in the cable termination compartment shall be
adequate to meet electrical and mechanical requirement besides facilitating
easy connections and disconnections of cables.
a) Each switchgear shall have a name plate for its identification. All enclosure
mounted equipment shall be provided with individual engraved name plates
for clear equipment identification. All panels shall be identified on front as
well as backside by large engraved name plates giving the distinct feeder
description along with panel numbers. Back side name plates shall be fixed
in panel frame and not on the rear removable cover.
10% spare feeders with at least one of each type of highest rating shall be provided in
each switchgear section.
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The bidder shall indicate the proposed makes of various bought out components such
as relays, CT’s, VT’s, control transformers, load breaker switch, fuse, contactor, push
button. Space heater, instruments etc. in the technical bidding schedule. However,
this shall not be bindings on the purchaser, final make shall be approved by the
purchaser/ consultant during detailed engineering to satisfy the specification
requirement.
5.1.7 Tests
a) Type Tests:
Reports of all type tests shall be submitted before dispatch for approval. In
case type test report on similar equipment (conducted within 10 years as on
the date of bid opening) is not available, these tests shall be carried out. The
bidder shall clearly indicate in his tender whether he would be furnishing the
type tests reports or he shall be conducting the tests along with the additional
cost for such tests, if any. The purchaser reserves the right either to waive the
type tests or get these type tests conducted.
b) Routine tests:
All routine tests as per relevant standards shall be conducted on the assembly
and the various components. The successful bidder shall submit five (5) copies
of certified test reports on all routine tests before dispatch for approval.
c) The purchaser reserves the right to witness all the tests. The tenderer shall
give at least three weeks clear notice prior to conducting these tests to enable
the purchaser and/or his representative to be present to witness the test.
d) Site Tests :
The following site tests shall be conducted as per the approved procedure to
be submitted during detailed engineering :
Visual inspection
Insulation Test
Calibration of relays & Instruments
Function / interlock test
Ratio and polarity for CTs and VTs
Breaker closing and tripping time
Anti-pumping operation
HV test on completely installed switchboard
The bidders shall furnish the following drawings and data with the bid.
a) Single line diagram and Bill of Material for every 11kV/6.6kV/3.3kV (as
applicable) switchboard including points of control.
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b) Single line diagram and schematic (interconnection) drawing of
11kV/6.6kV/3.3kV (as applicable) switchboards and 415V switchboard / MCCs/
distribution boards.
Frequency - 50 Hz
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Frequency - 50 Hz
c) General Requirements :
ii) The supplier shall connect tank / body frame and HV neutral terminal to the
earth mat. The HV neutral terminal shall be connected at two different points of
earth mat.
iv) A warning plate indicating “Switch shall be operated only when the Transformer
is de-energised” shall be fitted on the off circuit tap changer.
v) Terminal Arrangement :
The primary and secondary of the transformer shall be suitable for cables/ Bus
duct. The cable box shall be self supporting, weather proof to suit out door
service. It shall be designed for sufficient phase to phase and ground clearance.
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It shall be furnished complete with removable gland plate of non-magnetic
material. The terminals for bus duct connections shall be located in this box.
Stainless steel vermin proof, well ventilated and weather proof marshalling box
with water-tight hinged and padlocked door of a suitable construction shall be
provided for the transformer ancillary apparatus. The box shall have slopping
roof. Padlock along with duplicate keys shall be supplied for marshalling box.
The degree of protection shall be IP-55.
Cubicle illumination lamp with door switch and space heater with thermostat
and ON/OFF switch shall be provided. 1 no. 5 Amp. socket switch shall be
provided inside the cubicle.
vii) Standards :
All 415V switchgears (i.e. Power control centres (PCCs), Motor control centres
(MCCs)), 415V non-segregated phase bus duct, and DC Boards for FGD system shall
be provided.
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Circuit Air break, three pole, spring charged, horizontal draw out type,
Breakers suitable for electrical operation
Switchgear Fully draw out type, single front
MCC/ VDDC Fully draw out type, single front
ACDB/ DCDB Fixed type, single front
Note : In case of space constraint, double front switchgear can be accepted and shall
be decided by the utility as per site conditions.
5.3.3 Metering
The energy meters shall be provided as per the Central Electricity Authority
(Installation and Operation of Meters) Regulations,2006 and its amendments.
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However, the energy accounting and audit meters shall be provided on LV side of
each incoming transformer feeder of 415V buses.
Energy accounting and audit meters shall be of accuracy class of 0.2S. The accuracy
class of CTs and VTs shall not be inferior to that of associated meters. In case,
numerical relays having built-in features of energy measurement of requisite
accuracy are provided in switchgear, separate energy meter is not necessary.
a) Temperature rise - The temperature rise of the horizontal and vertical bus bars
and main bus link including all power draw out contacts when carrying 90% of
the rated current along the full run shall in no case exceed 550C with silver
plated joints and 400C with all other types of joints over an ambient of 500C.
b) Breakers
ii) The incomer and bus coupler breakers for switchgear shall be electrically
operated with over current releases or relays.
iii) Breakers shall have inherent fault making and breaking capacities. They
shall have shunt trip coils. In case releases are offered, the same shall have
contact for energization of lockout relay. All breakers shall have built in
interlocks for equipment and personnel safety.
v) Mechanical tripping shall be through red ‘Trip’ push button outside the
panels for breakers, and through control switches for other circuits.
vii)Clear status indication for each circuit shall be provided through lamps,
switch positions or other mechanical means.
i) Incomers for MCCs and DBs rated up to 400A shall be MCCB. Above 400A,
breaker shall be provided.
ii) Motor starter contactors shall be of air break, electromagnetic type suitable
for DOL starting of motor, and shall be of utilisation category AC-3 for
ordinary and AC-4 for reversing starters. DC contactor shall be of DC-3
utilisation category.
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iii) Fuses shall be HRC type with operation indicator. Isolating switches shall be
of AC 23A category when used in motor circuit, and AC 22A category for
other applications. Fuse switch combination shall be provided wherever
possible.
iv) Isolating switches and MCCBs shall have door interlocks and padlocking
facility.
d) Panels
i) All switchgears, MCCs, DBs, panels, modules, local starters and push
buttons shall have prominent engraved identification plates.
ii) Local push button stations shall have metal enclosure of die cast aluminium
or rolled sheet steel of 1.6mm thickness and shall be of DOP IP55. Push
buttons shall be of latch type with mushroom knobs.
vi) The incoming connection to transformer of more than 1000KVA and inter-
connecting sections between switchboards shall preferably be of bus
ducts. The bus duct enclosure shall be made of minimum 3mm thick
aluminium alloy. The section of the bus duct should have adequate
strength to withstand internal and external forces resulting from the various
operating conditions. Aluminium sheet hood shall be provided for outdoor
bus duct enclosure joints to provide additional protection against water
ingress. The bus duct top shall be sloped to prevent retention of water. The
bus duct shall have DOP of IP55.
viii) All draw-out modules shall be provided with “Closed door operation”
feature wherein movement of the module from “Isolated” position to
“Service” position & vice-versa and power ON / OFF operation of the
module shall be possible only with the module door closed condition.
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ix) The switchboards shall comply to the Internal arc fault containment tests of
50 kA for 0.3s.as per IEC/TR 61641.
i) All breaker feeders shall have Numerical relays. All relays, auxiliary relays
and devices shall be of reputed make and types proven for the application
and shall be subject to purchaser approval. The relays and timers shall
have appropriate setting ranges, accuracy, resetting ratio, transient over-
reach and other characteristics to provide required sensitivity to the
satisfaction of the owner.
ii) Relays shall be suitable for efficient and reliable operation of the protection
scheme. Necessary auxiliary relays, timers, trip relays, etc. required for
complete scheme, interlocking, alarm, logging, etc. shall be provided. No
control relay, which shall trip the circuit breaker when relay is de-energized,
shall be employed in the circuits.
iii) Relays shall be flush mounted on the front with connections at the rear.
Provision shall be made for easy isolation of trip circuits for testing and
maintenance.
iv) Relays shall be provided with self reset contacts except the trip, lockout
relays and interlocking (contact multiplication) relays which shall be manual
reset type
vii) Only DC/ DC converters shall be provided in the solid state devices/ relays
wherever necessary to provide a stable auxiliary supply for relay operation
viii) All relays shall have hand-reset flags or other means for ready visual
indication of their operation and also of the faulty phase.
ix) Control circuits shall operate at suitable voltage of 110V AC or 220V DC.
Necessary control supply transformers having primary and secondary
fuses shall be provided for each MCC, 2 x 100% per section. However, the
breakers shall operate on 220V DC The auxiliary bus bars for control
supply shall be segregated from main bus bars. The control supplies shall
be monitored.
xi) All relays and timers shall operate on available DC supply and not have
any inbuilt batteries. They shall be provided with hand-reset operation
indicator (flags) or LEDs with push buttons for resetting.
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xii) All meters/ instrument shall be flush mounted on front panel, at least 96
mm2 size with 900 linear scales and accuracy class of 1.0.
xiii) All motors of 30kW and above shall have an ammeter. Bus-section shall
have bus VT, voltmeter with selector switch, and other relay and timers
required for protection. Adequate control and selector switches, push
buttons and indicating lamps shall be provided. Thermostatically controlled
space heaters with switches shall be provided to prevent condensation.
xiv) All motors are required to have an emergency stop push button near the
motor.
Each feeder shall have local/ remote selector switch. Closing from local
shall be possible only in test position whereas closing from remote shall be
possible in either service or test position. Tripping from local shall be
possible only when local/ remote selector switch is in local position.
Tripping from remote shall be either breaker in service position or selector
switch being in remote position.
xvii) Transducers
a) Current transducers
- Input 0-1 A (CT secondary)
- Rated frequency 50 Hz
- Output 4-20 mA (2 Nos. decoupled) for meter/
DDCMIS
- Accuracy 0.5%
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5.3.5 Protection
a) Incomer to 415V Switch boards :
i. Instantaneous over current protection (50)
ii. Sync Check (25)
iii. Restricted earth fault protection for Transformer LV winding (64R).
iv. Lockout (86), preferably built in Numerical Relay
a) All 415V switchgears, AC and DC distribution boards (DBs) etc. shall have
following features :
i) Shall be of metal enclosed, indoor, floor mounted and free standing type.
ii) All frames and load bearing members shall be fabricated using mild steel
structural sections or pressed and shaped cold rolled sheet steel of
thickness not less than 2mm.
iii) Frame shall be enclosed in cold rolled sheet steel of thickness not less
than 2mm (CR). Doors and covers shall also be of cold rolled sheet steel
of thickness not less than 1.6 mm. Stiffeners shall be provided wherever
necessary. Removable gland plates of thickness 3mm (hot/cold rolled
sheet steel) or 4 mm (non-magnetic material) shall be provided for all
panels.
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iv) For motors of rating 110kW & above, remote controlled electrical circuit
breakers, and for smaller motors, switch-fuse contactor feeders shall be
provided. The other Outgoing feeders of rating 100A and above up to
400A shall have MCCBs and below 100A shall be Switch-fuse
Units(SFU).
v) The switchboards/ MCC/ DBs of 1600A and above rating shall be of DOP
IP42 and of IP52 for less than 1600A rating.
vi) All 415V switchgears, MCC’s, AC and DC distribution boards etc. shall be
painted by powder coating process. Paint shade for complete panels
excluding end covers shall be RAL9002 and RAL5012 for extreme end
covers of all boards.
vii) Minimum air clearance in air between phases and phase-earth shall be
25 mm for bus bars and cable terminations. For all other components, the
Clearances shall be at least 10mm. Wherever above is not possible
except for horizontal and vertical bus bars, insulation shall be provided by
anti tracking sleeving or barriers. However, for horizontal and vertical bus
bars, clearances specified above shall be maintained even when bus bars
are insulated/ sleeved. In case of DCDBs/ fuse boards, the bus bar
system shall be insulated or physically segregated with barriers to prevent
interpole short circuit.
viii) All current and voltage transformers as required for metering and
protection specified shall be completely encapsulated, cast resin
insulated type. Incomers from transformers shall have CTs for
transformer Restricted Earth Fault (REF) protection. All current and
voltage transformers as required for metering and protection specified
shall be completely encapsulated cast resin insulated type. Incomers
from transformers shall have CTs for transformer restricted earth fault
protection. The accuracy shall be as follows:
CTs PTs
Protection 5P20 3P
Metering 1.0 1.0
REF PS
5.3.7 Spare feeders - 20% spare feeders with at least one of each type and rating shall be
provided in each switchgear.
i) The section of three phase and neutral metal enclosed non segregated phase
bus duct shall be rectangular. The design of the bus duct enclosures shall be
of sturdy construction such that it will withstand the internal or external forces
resulting from the various operating conditions.
ii) The entire bus duct shall be designed for dust, vermin and weather proof
construction. A suitable aluminium sheet flange-protection hood shall be
provided to cover all outdoor bus duct enclosure joints to facilitate additional
protection against rain water ingress. All horizontal runs of bus duct shall have
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a suitable sloped enclosure top to prevent retention of water for both indoor and
out-door portion of bus ducts. Bus duct enclosure shall have a degree of
protection of IP-55.
iii) The inside of the bus enclosure may be treated with black paint to enable
efficient heat dissipation. The matt paint used shall be suitable for temperature
experienced during continuous loading of the bus conductor.
iv) Enclosures shall be provided with flanged ends with drilling dimensions to suit
the flanges at the switchgear and transformer terminals.
vii) The material of the conductor shall be aluminium. The bus bars shall be rated
in accordance with the service conditions and the rated continuous and short
time current ratings.
viii) All steel structures required for bus duct support shall be hot dip galvanised.
a) Type Non-Segregated
b) 1 minute power frequency withstand voltage 2.5 kV
c) Maximum short circuit withstand current 50kA for 1 second
d) Momentary dynamic current withstand 105kA (Peak)
All the HT and LT motors as required for FGD Plant shall be provided.
i. All motors upto200kW rating shall be 3 phase, 415V squirrel cage Induction
motors.
ii. Motors of rating above 200kW and up to 1500kW shall be rated for 6.6/3.3kV
voltage and above 1500kW shall be rated for 11/6.6kV.
iii. All motors of rating 30kW and above shall be provided with single phase 240V
space heaters.
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i) All the motors shall be suitable for an ambient temperature of 500C and relative
humidity of 95%. The motors shall be suitable for operation in a highly polluted
environment
ii) Voltage and Frequency variations: All motors shall be suitable for following
variations
v) System grounding
1) Indoor motors IP 55
2) Outdoor motors IP 55
3) Cable box – indoor area IP 55
4) Cable box – outdoor area IP 55
5.4.3 Type
i) AC Motors:
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motor. Motor operating through variable frequency drives shall be suitable
for inverter duty. Also these motors shall comply the requirements stipulated
in IEC: 60034-18-41 and IEC: 60034-18-42 as applicable.
5.4.4 Rating
i) Continuously rated (S1). However, crane motors shall be rated for S4 duty i.e.
40% cyclic duration factor.
ii) Maximum continuous motor ratings shall be at least 10% above the maximum
load demand of the driven equipment unless otherwise specified, under entire
operating range including voltage and frequency variations.
Air cooled motors 70 C by resistance method for both class 130(B) and
155(F) insulation
Water cooled 80 C over inlet cooling water temperature, by
motors resistance method for both class 130(B) and 155(F)
insulation
i) Starting Time
b) For motors with starting time more than 20secs. and up to 45secs. at
minimum permissible voltage during starting, the locked rotor withstand time
under hot condition at highest voltage limit shall be at least 5 secs. more
than starting time.
c) For motors with starting time more than 45secs. at minimum permissible
voltage during starting, the locked rotor withstand time under hot condition
at highest voltage limit shall be more than starting time by at least 10% of
the starting time.
b) Pull out torque at rated voltage shall not be less than 205% of full load
torque. It shall be 275% for crane duty motors.
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iii) Starting voltage requirement
i) Suitable single phase space heaters shall be provided on motors rated 30kW
and above to maintain windings in dry condition when motor is standstill.
Separate terminal box for space heaters and RTDs shall be provided.
ii) All motors shall be either totally enclosed fan cooled (TEFC) or totally enclosed
tube ventilated (TETV) or closed air circuit air cooled (CACA) type. However,
motors rated 3000 kW or above can be closed air circuit water cooled (CACW).
The method of movement of primary and secondary coolant shall be self-
circulated by fan or pump directly mounted on the rotor of the main motor as
per IEC 60034-6. However, VFD driven motors can be offered with forced
cooling type with machine mounted fan or pump driven by separate electric
motor.
iii) For hazardous location such as fuel oil facilities area, the enclosure of motors
shall have flame proof construction conforming to IS:2148 as detailed below:
v) Motors rated above 1000KW shall have insulated bearings to prevent flow of
shaft currents.
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vi) Motors with CACA or CACW enclosure shall have dial type thermometer with
adjustable alarm contacts to indicate inlet and outlet primary air temperature.
vii) Noise level and vibration shall be limited within the limits prescribed in IS: 12065
and IS/IEC 60034-14 respectively.
viii) In 11kV,6.6kV and 3.3kV motors, at least four numbers simplex/ two numbers
duplex platinum resistance type temperature detectors shall be provided for
each phase of stator winding. Each bearing shall preferably be provided with
dial type thermometer with adjustable alarm contact and two numbers duplex
platinum resistance type temperature detector Motor body shall have two
earthing points on opposite sides.
ix) 11 kV motors shall be offered with Separable Insulated Connector (SIC) as per
IEEE 386. The offered SIC terminations shall be provided with protective cover
and trifurcating sleeves. SIC termination kit shall be suitable for fault level of 25
kA for 0.17 seconds.
3.3/6.6 kV motors shall be offered with dust tight phase separated double
walled (metallic as well as insulated barrier) Terminal box. Suitable termination
kit shall be provided for the offered Terminal box. The offered Terminal Box
shall be suitable for fault level of 250 MVA for 0.12 sec. Removable gland plates
of thickness 3 mm (hot/cold rolled sheet steel) or 4 mm (non-magnetic material
for single core cables) shall be provided.
x) All motors shall be so designed that maximum inrush currents and locked rotor
and pullout torque developed by them at extreme voltage and frequency
variations do not endanger the motor and driven equipment.
xi) The motors shall be suitable for bus transfer schemes provided on the 11kV,
6.6kV, 3.3 kV, 415V systems without any injurious effect on its life.
xii) Motors rated 2000kW and above shall be provided with neutral current
transformers of PS class on each phase in a separate neutral terminal box for
differential protection.
xiii) The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the
following (without any further tolerance) :
(a) From 50KW & up to 110KW : 11.0
(b) From 110 KW & up to 200 KW : 9.0
(c) Above 200 KW & up to 1000KW : 10.0
(d) From 1001KW & up to 4000KW : 9.0
(e) Above 4000KW : 6 to 6.5
The following type tests shall be conducted on each type and rating of HT motor:
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e) Temperature rise test at rated conditions. During heat run test, bearing temp.,
winding temp., coolant flow and its temp. shall also be measured. In case the
temperature rise test is carried at load other than rated load, specific approval for
the test method and procedure is required to be obtained. Wherever ETD's are
provided, the temperature shall be measured by ETD's also for the record purpose.
The following type test reports shall be submitted for each type and rating of HT motor:
a) Degree of protection test for the enclosure followed by IR, HV and no load run test.
b) Terminal box-fault level withstand test for each type of terminal box of HT motors
only.
c) Lightning Impulse withstand test on the sample coil shall be as per clause no. 4.3
IEC-60034, part-15
d) Surge-withstand test on interturn insulation shall be as per clause no. 4.2 of IEC
60034, part-15
In case the contractor has conducted such specified type test(s) within last ten
years as on the date of bid opening, he may submit during detailed engineering the
type test reports to the employer for waival of conductance of such test(s). These
reports should be for the tests conducted on the equipment similar to those
proposed to be supplied under this contract and test(s) should have been either
conducted at an independent laboratory or should have been witnessed by a client.
The employer reserves the right to waive conducting of any or all the specified type
test(s) under this contract. In case type tests are waived, the type test charges shall
not be payable to the contractor.
All 11kV, 6.6kV, 3.3kV and 415V power cables, control cables and DC cables required
to connect auxiliaries shall be supplied.
All cables to be supplied shall conform to the latest revisions of IS or any other
international standards acceptable to purchaser. Some of the Indian Standards/ IEC
considered relevant to the cables are given below:
IS:1554(Part-I) PVC insulated (heavy duty) electric cables for working voltage up
to and including 1100 V.
IS:1554 (Part-II) PVC insulated (heavy duty) electric cables for working voltage from
3.3kV up to and including 11kV.
IS:7098 (Part-III) XLPE insulated PVC sheathed cables for working voltages from
3.3 kV up to and including 33kV.
IS:3961 Recommended current ratings for cables.
IS:8130 Conductors for insulated electric cables and flexible cords.
IS:5831 PVC insulation and sheath of electric cables.
IS:2982 Copper conductor in insulated cables and cords.
IS:3975 Mild steel wires, strips and tapes for armouring cables
IS:5609 Specification for low frequency wires and cables with PVC
insulation and PVC Sheath.
IS:6380 Spec. of elastomeric insulation of sheath of electric cables.
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i) The cable shall be suitable for installation in a tropical monsoon area having a
hot humid climate. The reference ambient temperature to be considered for
the purpose of this specification is 500C.
ii) The derating factor for the various conditions of installation including the
following shall be considered while choosing the conductor size and
calculations shall be submitted for purchaser’s approval:
a) Maximum ambient air temperature.
b) Maximum ground temperature
c) Depth of laying wherever applicable
d) Grouping of cables
iii) The allowable voltage drop at terminal of the connected equipment shall be
maximum 2.5 % at full load while choosing the conductor size and calculations
shall be submitted for purchaser’s approval. In case of squirrel cage induction
motors, the cable size shall be so chosen that the motor terminal voltage does
not fall below 85% of the rated voltage, at the time of starting.
iv) The maximum continuous conductor temperature and the maximum allowable
conductor temperature during short circuit are to be taken as 70oC and 160oC
respectively in case of PVC insulated cables and 90oCand 250oCrespectively
in case of XLPE insulated cables.
v) The minimum size of all 11kV (UE), 3.3kV (UE) grade power cables and 415V
power cables connected to circuit breakers shall be chosen taking into account
the following factors:
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b) Fault contribution of running motors.
c) Expected time up to which motor contribution persists.
d) Maximum time for fault clearance (i.e. operating time of the back-up
protection relays plus the time of operation of the circuit breakers).
e) Full load current of the circuit.
vi) The cables shall be capable of continuous satisfactory operation under a power
supply system frequency variation of (±) 5%, voltage variation of (±)10% and
combined frequency and voltage variation of 10% (absolute sum).
vii) The cables shall in general comply with the requirements of the latest
revision of IS:7098 (Part-II) for the 11kV (UE), 6.6kV, 3.3kV grade, XLPE
insulated cables, IS:7098 (Part-I) for LT XLPE insulated and IS:1554 (Part-I) for
the LT PVC power and control cables or the relevant IEC International Standard
unless otherwise specified in this specification. The design, manufacture,
installation, testing and performance of the cables, shall comply with the latest
revisions of IS/ IEC/ NEMA/ ASTM Standard and the most stringent conditions
specified in these specification shall be applicable.
ii) Conductor
The cable conductor shall be made from standard copper/ Aluminum to form
compact conductor having a resistance within the limits specified.
All the cables of size 25mm2 and above shall have sector shaped conductors.
The minimum no. of strands in conductor shall be 7 (seven) except as otherwise
specified. Power cables shall be of stranded aluminum conductor with a
minimum size 6mm2 and the control cables shall be stranded copper
(electrolytic) conductor with a minimum size of 2.5 mm2.
iv) Insulation
The insulation of the cable shall be extruded type and shall be designed and
manufactured for the specified system voltage. The manufacturing process
shall ensure that insulation shall be free from voids. The insulation shall
withstand mechanical and thermal stresses under steady state and transient
operating conditions. The extrusion method should give a very smooth
interface between semi conducting screen and insulati0on. The insulation of
the cables shall be of high standard quality. The minimum volume resistivity of
the PVC insulation of all the PVC insulated cables shall be 1x1014 ohm-cm at
27oC and 1x1011 ohm-cm at 70oC.
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v) Insulation shield
In XLPE cables to confine electrical field to the insulation, a non-magnetic semi-
conducting shield shall be put over the insulation. The insulation shield shall
be extruded in the same operation as the conductor shield and the insulation
by triple extrusion/process. The XLPE cable insulation shield shall be
strippable. Metallic screening as given in this specification for the various
power and control and special cables shall be provided.
vi) Sheath
The sheath shall be suitable to withstand the site conditions and the desired
temperature. It shall be of adequate thickness and applied by a continuous
process to produce a sheath of consistent quality free from all defects. PVC
sheath shall be extruded.
vii) Armour
Hard drawn aluminum wire armouring/ galvanized steel tape/ wire armouring
shall be used for single core and multi-core cable respectively.
The hard drawn aluminium wire for armour shall be of H4 grade, as per IS-8130
(having tensile strength above 150 N/mm2) The diameter of the aluminium wire
shall be as per the table for the dimensions of the galvanized steel wire armour
given in the relevant standard.
Extruded PVC serving as per IS: 5831 or as specified otherwise shall be applied
over the armouring with suitable additives to prevent attach by rodent and
termites. All serving must be given anti-termite treatment.
i) Cable shall have suitable filters laid up with the conductors to provide a
substantially circular cross section before the sheath is applied. Fillers shall be
suitable for the operating temperature of the cable and compatible with the
insulating material. All materials shall be new, unused and of finest quality.
Workmanship shall be neat, clean and of highest grade.
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ST2 outer sheathed.
d) 415V system power cables - The cable shall be 1.1kV, grade, heavy duty,
stranded aluminium conductor, PVC Type-A Insulated galvanized steel
wire/strip armoured, flame retardant low smoke (FRLS) extruded PVC type
ST1 outer sheathed. XLPE insulated cables shall also be acceptable.
e) Control cables - The cable shall be 1.1kV grade, heavy duty, stranded
copper conductor, PVC Type-A insulated, galvanized steel wire/ strip
armoured, flame retardent low smoke (FRLS) extruded PVC of Type-ST1
outer sheathed.
ii) Special properties - All the above cables shall be conforming to the relevant
Indian/ IEC standard in general, with the following special properties:
a) Oxygen Index of the outer sheath shall not be less than 29, when tested as
per ASTM-D-2863.
b) Temperature Index of the outer sheath shall not be less than 250oC, when
tested as per ASTM-D-2863.
c) Halogen acid contents in outer sheath shall not be more than 20%, when
tested as per IEC-60754.
d) The maximum smoke density in percent light absorption should not exceed
60% in case of PVC compound and 20% in case of fire survival cables, when
tested as per ASTM-D-2843.
e) Swedish chimney test as per SS-4241475 class F3 and ladder test for
flammability as per IEEE-383.
iii) Fire survival cables - The cable shall be of copper conductor and comply with
IEC-60331 in addition to the above requirement. Also the halogen acid contents
in outer sheath shall not be more than 2% when tested and per IEC-60754 and
the smoke density in percent light absorption shall not exceed 20% when tested
as per ASTM-D- 2843.
The insulated cores of HT and LT power cables shall be identified by coloured code.
The control cables shall have identification by means if indelible printing of numbers of
its cores at intervals not more than 75 mm. At least 20% cores shall be kept as spares
in the multi-core control cables.
As far as feasible, separate cables shall be provided for circuits of different plant and
auxiliaries, for circuits of different voltages, and for circuit used separately. Power,
control and instrumentation circuit shall invariably be taken through different routes,
which shall not be laid together on the same cable trays.
Drum lengths of the cables shall be so chosen that straight through joints are
eliminated. However, the drum lengths shall not be less than the following lengths:
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Section- 5 (Electrical Works)
1. The cable trays, and accessories, supports, conduits, cable glands, lugs, ferrules,
tags, clamps and other accessories for installation of cables in cable galleries,
trenches etc. for auxiliaries; earthing system network/ earth mat including
interconnections; and lightning protection of service buildings and other tall
structures shall be provided.
2. The supply, laying and termination of bidder’s cables shall include installation of
cable facilities viz. cable trays and conduits, supports, trays, lugs, terminals, tags,
clamps etc. as required.
3. All cables shall be run in GI cable trays / rigid GI conduits as far as possible. The
bidder has the option to make use of existing cable facilities to the extent feasible
without causing any damage/disruption.
4. The bidder shall carefully examine the possibility of making use of the existing
cable facilities before preparing his offer with a view to correctly estimate the
quantity of cable trays/conduits that would have to be supplied and installed by
him.
All work shall be carried out as per the following standards/ codes as applicable.
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IS:8308 Compression type tubular in- line connectors for aluminium conductors
of insulated cables
IS:8309 Compression type tubular terminal ends for aluminium conductors of
insulated cables.
IS:9537 Conduits for electrical installation.
IS:9595 Metal arc welding of carbon and carbon manganese steels-
recommendations.
IS:13573 Joints and terminations for polymeric cables for working voltages from
6.6kV up to and including 33kV performance requirements and type
tests.
BS:476 Fire tests on building materials and structures
IEEE:80 IEEE guide for safety in AC substation grounding
IEEE:142 Grounding of Industrial and commercial power systems
DIN 46267 Non tension proof compression joints for Aluminium conductors.
(Part-II)
DIN 46329 Cable lugs for compression connections, ring type ,for Aluminium
conductors
VDE 0278 Tests on cable terminations and straight through joints
BS:6121 Specification for mechanical Cable glands for elastomers and plastic
insulated cables.
Interplant cabling for main routes shall be laid along overhead trestles/duct
banks/buried cables. However, from tap-offs, same can be through shallow
trenches/ support taken from nearest building/ structure. In case of Duct banks,
pull-pits shall be filled with sand and provided with a PCC covering. Directly
buried cables, if essential, shall not have concentration of more than 4 cables
in one route.
ii) Cable entry - Cable entry from outdoor underground/ cable routes to the
buildings, if any, shall be above the finished floor level of the building.
iii) Trenches - PCC flooring of built up trenches shall be sloped for effective
drainage with sump pits and sump pumps.
iv) No sub-zero level cable vault/ trenches shall be provided below control building/
switchgear rooms.
b) Cable trays, fittings and accessories shall be fabricated out of rolled mild
steel sheets free from flaws such as laminations, rolling marks, pitting etc.
These (including hardware) shall be hot dip galvanized as per relevant IS.
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Section- 5 (Electrical Works)
c) Cable trays shall have standard width of 150 mm, 300 mm and 600 mm and
standard lengths of 2.5 metre. Minimum thickness of mild steel sheets used
for fabrication of cable trays and fittings shall be 2 mm. The thickness of side
coupler plates shall be minimum 3 mm .
b) Support system for cable trays shall essentially comprise of the two
components i.e. main support channel and cantilever arms. The main
support channel shall be of two types : i) C1: having provision of supporting
cable trays on one side and ii) C2: having provision of supporting cable trays
on both sides. The support system shall be as follows :
- The system shall be designed such that it allows easy assembly at site
by using bolting. All cable supporting steel work, hardwares fittings and
accessories shall be prefabricated factory galvanized.
- The main support and cantilever arms shall be fixed at site using
necessary brackets, clamps, fittings, bolts, nuts and other hardware etc.
to form various arrangements required to support the cable trays. Welding
of the components shall not be allowed. However, welding of the bracket
(to which the main support channel is bolted) to the overhead beams,
structural steel, insert plates or reinforcement bars will be permitted. Any
cutting or welding of the galvanized surface shall be brushed and red lead
primer, oil primer and aluminium paint shall be applied.
- All steel components, accessories, fittings and hardware shall be hot dip
galvanized after completing welding, cutting, drilling and other machining
operation.
- The main support channel and cantilever arms shall be fabricated out of
minimum 2.5 thick rolled steel sheet conforming to IS.
- Cantilever arms of 300 mm, 450mm, 600 mm and 750 mm in length are
required. The arm portion shall be suitable for assembling the complete
arm assembly on to component constructed of standard channel section.
The back plate shall allow sufficient clearance for fixing bolt to be
tightened with tray in position.
a) Pipes offered shall be complete with fittings and accessories (like tees,
elbows, bends, check nuts, bushings, reducers, enlargers, coupling caps,
nipples etc.) The size of the pipe shall be selected on the basis of maximum
40% fill criteria
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b) GI Pipes shall be of medium duty as per IS:1239.
c) Duct banks shall be high density PE pipes encased in PCC (10% spare of
each size, subject to minimum one) with suitable water-proof manholes.
a) Junction Boxes with IP:55 degree of protection, shall comprise of a case with
hinged door constructed from cold rolled sheet steel of minimum thickness
2mm. Top of the boxes shall be arranged to slope towards rear of the box.
Gland plate shall be 3mm thick sheet steel with neoprene/ synthetic rubber
gaskets. All junction boxes shall be of adequate strength and rigidity, hot dip
galvanized as per relevant IS, and suitable for mounting on wall, columns,
structures etc. The boxes shall include brackets, bolts, nuts, screws M8
earthing stud etc. required for installation
b) Terminal blocks shall be 650 volts grade, rated for 10 Amps and in one piece
moulding. It shall be complete with insulating barriers, Klip-on-type terminals
and identification strips. Marking on terminal strip shall correspond to the
terminal numbering on wiring diagrams. It shall be Elmex type CSLT-1 with
insulating material of Melamine conforming to ESI Standard 12.1 or
equivalent. Terminal block shall be suitable for terminating 2 wires of 2.5mm2
on both sides arranged to facilitate easy termination
Cable shall be terminated using double compression type cable glands. Cable
glands shall conform to BS:6121 and be of robust construction capable of
clamping cable and cable armour (for armoured cables) firmly without injury to
insulation. Cable glands shall be made of heavy duty brass machine finished
and nickel chrome plated. Thickness of plating shall not be less than 10 micron.
All washers and hardware shall also be made of brass with nickel chrome
plating Rubber components shall be of neoprene and of tested quality.
Necessary cable dimensions shall be furnished to the successful bidder.
Cable lugs for power cables shall be Aluminium solderless crimping type
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Section- 5 (Electrical Works)
conforming to IS:8309 suitable for aluminium compacted conductor cables.
Cable lugs and ferrules for control cables shall be tinned copper conforming to
IS:8309. The cable lugs for control cables shall be provided with insulating
sleeve and shall suit the type of terminals provided on the equipments.
Trefoil clamps for single core cables shall be pressure die cast aluminum or
fibre glass or nylon and shall include necessary fixing accessories like G.I. nuts,
bolts, washers, etc. Trefoil clamps shall have adequate mechanical strength to
withstand the forces generated by the system short circuit current of 105 KA
peak.
The cable clamps required to clamp multicore cables on vertical run shall be
made up of Aluminium strip of 25x3 mm size. For clamping the multicore
cables, self-locking, de-interlocking type nylon clamps/ straps shall be used.
The clamps/ straps shall have sufficient strength and shall not get affected by
direct exposure to sun rays and outdoor environment.
x) Receptacles
xi) Galvanizing
b) The amount of zinc deposit over threaded portion of bolts, nuts, screws and
washers shall be as per IS:1367. The removal of extra zinc on threaded
portion of components shall be carefully done to ensure that the threads
shall have the required zinc coating on them as specified.
xii) Welding
The welding shall be carried out in accordance with IS:9595. All welding
procedures and welders qualification shall also be followed strictly in line with
IS:9595.
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Section- 5 (Electrical Works)
5.6.4 Installation
c) The cantilever arms shall be positioned on the main support channel with a
minimum vertical spacing of 300 mm unless otherwise indicated in the
relevant tray layout drawings
d) All cable way sections shall have identification, designations as per cable
way layout drawings and painted/stenciled at each end of cable way and
where there is a branch connection to another cable way. Minimum height
of letter shall be not less than 75 mm. For long lengths of trays, the
identification shall be painted at every 10 meter. Risers shall additionally be
painted/ stenciled with identification numbers at every floor.
a) All openings in the floor/ roof/ wall / cable tunnel/ cable trenches made for
conduit installation shall be sealed and made water proof.
b) GI pull wire of adequate size shall be laid in all conduits before installation.
Metallic conduit runs at termination shall have two lock nuts wherever
required for junction boxes etc.
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Section- 5 (Electrical Works)
square and true to line and grade with an average spacing between the
supports as given below, unless specified otherwise:
a) Cable installation shall be carried out as per IS:1255 and other applicable
standards. Cable drums shall be unloaded, handled and stored in an
approved manner on hard and well drained surface so that they may not
sink. In no case shall be drum be stored flat i.e. with flange horizontal. Rolling
of drums shall be avoided as far as possible. For short distances, the drums
may be rolled provided they are rolled slowly and in proper direction as
marked on the drum. In absence of any indication, the drums may be rolled
in the same direction as it was rolled during taking up the cables. For un-
reeling the cable, the drum shall be mounted on suitable jacks or on cable
wheels and shall be rolled slowly so that cable comes out over the drum and
not from below. All possible care shall be taken during unreeling and laying
to avoid damage due to twist, kink or sharp bends. Cable ends shall be
provided with sealed plastic caps to prevent damage and ingress of
moisture.
b) While laying cable, ground rollers shall be used at every 2 metre interval to
avoid cable touching ground. The cables shall be pushed over the rollers by
a gang of people positioned in between the rollers. Cables shall not be pulled
from the end without having intermediate pushing arrangements. Pulling
tension shall not exceed the values recommended by cable manufacturer.
Selection of cable drums for each run shall be so planned so as to avoid
using straight through joints. Care should be taken while laying the cables
so as to avoid damage to cables.
c) Cables shall be laid on cable trays strictly in line with cable schedule
furnished.
d) Power and control cables shall be laid on separate tiers. The laying of
different voltage grade cables shall be on different tiers according to the
voltage grade of the cables. In horizontal tray stacks, HT cables (11kV) shall
be laid on topmost tier and cables of subsequent lower voltage grades on
lower tiers of trays. Single core cable in trefoil formation shall be laid with a
distance of four times the diameter of cable between trefoil center lines and
clamped at every two metre. All multi-core cables shall be laid in touching
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Section- 5 (Electrical Works)
formation. Power and control cables shall be secured fixed to trays/ support
with self locking type nylon cable straps with de-interlocking facilities. For
horizontal trays arrangements, multi-core power cables and control cables
shall be secured at every five meter interval. For vertical tray arrangement,
individual multi-core power cables and control cables shall be secured at
every one meter by nylon cable strap. After completion of cable laying work
in the particular vertical tray, all the control cables shall be binded to trays/
supports by aluminium strips at every five meter interval and at every bend.
f) Where cables cross roads/rail tracks, the cables shall be laid in hume pipe/
PVC pipe.
g) Joints for less than 250 Meters run of cable shall not be permitted.
h) In each cable run some extra length shall be kept at suitable point to enable
one LT (415V system) / two HT (11/6.6kV, 3.3kV) straight through joints to
made, should the cable develop fault at a later stage. Control cable
termination inside equipment enclosure shall have sufficient lengths so that
shifting of termination in terminal blocks can be done without requiring any
splicing.
i) Wherever few cables are branching out from main trunk route troughs shall
be used.
j) The installation work shall be carried out in a neat workman like manner and
areas of work shall be cleaned of all scraps, water, etc. after the completion
of work in each area every day. RCC/ Steel trench covers shall be replaced
after the installation work in a particular area is completed or when further
work is not likely to be taken up for some time.
l) Segregation
- All cables associated with the unit shall be segregated from cables of
other units.
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control cables shall be as follows :
Wherever the cables pass through walls/ floors, fire proof cable penetration
seals rated for two hours shall be provided. This shall be by suitable block
system using individual blocks with suitable framework or by silicon RTV
foaming system. In case foaming system is offered, damming board, if used,
shall not be considered for fire rating criteria. Any of the system offered shall
be of proven type as per BS:476 (Part-20) or equivalent standard.
- RCC cable route and RCC joint markers shall be provided wherever
required. The voltage grade of the higher voltage cables in route shall
be engraved on the marker. Location of underground cable joints shall
be indicated with cable marker with an additional inscription “Cable
Joint”. The marker shall project 150 mm above ground and shall be
spaced at an interval of 30 meters and at every change in direction.
They shall be located on both sides of road crossings and drain
crossings. Top of cable marker/joint marker shall be sloped to avoid
accumulation of water/dust on marker.
p) Cable tags shall be provided on all cables at each end (just before entering
the equipment enclosure), on both sides of a wall or floor crossing, on each
duct/conduit entry, and at every 20 meters in cable tray/trench runs. Cable
tags shall also be provided inside the switchgear, motor control centers,
control and relay panels etc. where a number of cables enter together
through a gland plate. Cable tag shall be of rectangular shape for power
cables and control cables. Cable tag shall be of 2 mm thick aluminum with
number punched on it and securely attached to the cable by not less than
two turns of 20 SWG GI wire conforming to IS:280. Alternatively, cable tags
made of nylon, cable marking ties of ‘TY-CAB’ or equivalent type with cable
number heat stamped on the cable tags may also be provided.
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v) Cable terminations and connections
b) Work shall include all clamps, fittings etc. and clamping, fitting, fixing,
plumbing, soldering, drilling, cutting, taping, preparation of cable end,
crimping of lug, insulated sleeving over control cable lugs, heat shrinking
(where applicable), connecting to cable terminal, shorting and grounding as
required to complete the job.
c) The equipment will be generally provided with undrilled gland plates for
cables/ conduit entry. The Contractor shall be responsible for punching of
gland plates, painting and touching up. Holes shall not be made by gas
cutting. The holes shall be true in shape. All cable entry points shall be
sealed and made vermin and dust proof. Unused openings shall be
effectively sealed by 2mm thick aluminium sheets.
d) Control cable cores entering control panel/ switchgear/ MCCs etc. shall be
neatly bunched, clamped and tied with self locking type nylon cable ties
with de interlocking facility to keep them in position.
e) The panels where a larger number of cables are to be terminated and cable
identification may be difficult, each core ferrule shall include the complete
cable number as per the drawings. The ferrules shall be indelible interlocking
type and shall fit tightly on cores. Spare cores shall have similarly ferrules
with a suffix letter ‘S’ along with cable numbers and coiled up after end
sealing.
i) Earthing system shall be in strict accordance with IS:3043/ IEEE-80/ IEC and
Indian Electricity Rules/ Acts.
Wherever existing main earthing system is not available, the main earthing
system will be designed considering suitable corrosion allowance based on
earthing conductor material and type of soil, for a service life of at least forty
(40) years for maximum fault current or system fault current of 40kA whichever
is higher for 1 second. The minimum rate of corrosion of earthing conductor
shall be considered as 0.12mm per year while determining the conductor size.
ii) The earth conductors shall be free from pitting, laminations, rust, scale and
other electrical, mechanical defects.
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iv) The sizes of earthing conductors for various electrical equipments shall be as
below:
iv) Metallic frame of all electrical equipment shall be earthed by two separate and
v) distinct connections to earthing system, each of 100% capacity, Crane rails,
tracks, metal pipes and conduits shall also be effectively earthed at two points.
Steel RCC columns, metallic stairs, and rails etc. of the building housing
electrical equipment shall be connected to the nearby earthing grid conductor
by one earthing ensured by bonding the different sections of hand rails and
metallic stairs. Metallic sheaths/screens, and armour of multi-core cables shall
be earthed at both ends. Metallic Sheaths and armour of single core cables
shall be earthed at switchgear end only. Every alternate post of the switchyard
fence shall be connected to earthing grid by one GS flat and gates by flexible
lead to the earthed post.
vi) Each continuous laid lengths of cable tray shall be earthed at minimum two
places by GS flats to earthing system, the distance between earthing points
shall not exceed 30 metre. Wherever earth mat is not available Contractor shall
do the necessary connections by driving an earth electrode in the ground.
vii) Neutral connections and metallic conduits/pipes shall not be used for the
equipment earthing. Lightning protection system down conductors shall not be
connected to other earthing conductors above the ground level.
viii) Connections between earth leads and equipment shall normally be of bolted
type. Contact surfaces shall be thoroughly cleaned before connections.
Equipment bolted connections after being tested and checked shall be painted
with anti corrosive paint/compound.
ix) Suitable earth risers shall be provided above finished floor/ground level, if the
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equipment is not available at the time of laying of main earth conductor.
xi) Resistance of the joint shall not be more than the resistance of the equivalent
length of conductors.
xii) Earthing conductors along their run on columns, walls, etc. shall be supported
by suitable welding/ cleating at interval of 1000mm and 750mm respectively.
xiii) Earth pit shall be constructed as per IS:3043. Electrodes shall be embedded
below permanent moisture level. Minimum spacing between electrodes shall
be 600mm. Earth pits shall be treated with salt and charcoal if average
resistance of soil is more than 20 ohm metre.
xiv) Earthing conductor shall be buried at least 2000mm outside the fence of
electrical installations. Every alternate post of the fences and all gates shall be
connected to earthing grid by one lead.
i) All lightning protection installation work shall be in accordance with the Indian
Electricity Rules and IS Code of Practice for the Protection of Buildings and
allied Structures against Lightning (IS:2309).
ii) Lightning protection system shall comprise vertical air terminations, horizontal
air terminations, down conductors, test links and earth electrodes.
iii) Air terminations, down conductors and test links shall be of galvanized steel
conductors and earth connection below ground level shall be of mild steel rod.
iv) For tall buildings and structures, early streamer emission (ESE) type air
terminal systems such as marketed by Heary Brothers (USA) are preferred.
vi) Horizontal air termination flats provided on top of control building, pump houses
and other buildings shall be laid such that no part of the roof shall be more than
9 meters
viii) Down conductors shall be cleated on outer side of building wall at 1000 mm
interval or tack welded to outside of building columns at 1000 mm interval.
ix) Down conductors shall be connected to separate earth electrodes through test
points located at height of above 1000 mm above ground level. These earth
electrodes shall in turn be connected to earth mat at two points.
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x) Lightning protection conductors shall not pass through or run inside GI
conduits.
xi) All metallic equipments on roof and exposed steel works within the vicinity of
2000 mm from lightning protection conductors in air shall be bonded to
conductors of lightning protection system.
xii) Lightning protection system shall have as few joints as possible and avoid sharp
bends. Down conductors shall have, as far as possible, no joint except at test
point and end termination.
5.7 LIGHTING
All components such as lighting fixtures, lighting/ welding branch boards/ Distribution
boards, switches, sockets, MCBs, MCCBs etc. must be of standard reputed make.
The bidder shall propose makes of the various components in his offer for proper
assessment. The makes proposed by the bidder in his bid shall however not be
binding on the purchaser and the same shall be finally decided during detailed
engineering with a view to meet the specification requirements.
The equipment supplied by the contractor shall be suitable for installation in an area
having hot and humid climate and dusty atmosphere.
In this system, the lighting circuits would be fed on the normal A.C. supply
available from the Main lighting boards. All the lighting fixtures connected to
this system shall be ‘ON’ as long as the 415/240V normal supply is healthy.
At strategic locations in the main building, control building, pump house viz.
near entrance, stair-case landing, important control points etc. permanent type
incandescent AC/DC lighting fixtures shall be provided to enable safe
movement of operating personnel and access to important control points during
station emergency involving total AC system failure.
The complete lighting of the FGD plant shall be met through 2 or 3 nos. Main Lighting
Boards. Each main Lighting Board shall be having Dry type 415 V/ 415 V lighting
transformer of adequate rating. The main lighting boards shall feed various lighting
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distribution boards to be located suitably near individual load centres. The incoming
supply to Main Lighting Board shall be arranged from 415V Switchboard to be supplied
by the bidder, through 1.1 kV grade armoured cable. MLBs shall be having MCCBs of
adequate rating for incoming supply and outgoing feeder.
The outgoing feeders power from MLB shall be taken through stranded Aluminium
conductor, PVC insulated, 1.1kV grade, armoured cable of appropriate size and shall
be terminated on lighting distribution boards (LDB). The required number of LDB shall
be wall mounting type having sheet metal enclosure, 3X63A copper bus bars and 63A
Neutral terminal block.
The incoming cables shall be terminated on 63A TPN switch and 4 nos. MCBs each
of 16A rating shall be provided on each of the three phases (i.e. total of 12 O/G MCBs)
for outgoing circuits. The minimum interrupting capacity of the miniature circuit breaker
(MCB) shall be 9kA rms. The LDB enclosure shall be duly earthed as specified.
The LDBs shall be located near entry doors. The LDB door shall have a cut out for
operating the MCBs. The cut out portion shall have a transparent plastic/acrylic cover
for its protection against dust. The LDB shall be of dust proof design.
Indoor Areas
i. Working plane shall be assumed about 800 mm above the finished ground
level.
ii. Fluorescent luminaries with pendant suspensions shall be installed 3.5 metre
above the finished floor level.
iii. Maintenance factor shall be taken as 0.7.
iv. Average illumination level shall be taken in the horizontal plane as specified.
Outdoor Areas:
The following table gives the desired average illumination level, recommended
luminaire type, reflection factors and maintenance factors applicable to various rooms/
areas :
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All luminaire to be supplied complete with lamps, starting gear and all necessary
accessories for mounting on ceiling/ poles/ false ceiling as required. Pendants/
brackets of suitable sizes shall be provided as required.
i. Type IRF (2 x 40 W)
ii. Type IF (1 x 40 W)
Similar to type IRF but without reflector and with 1 x 40 W fluorescent tube.
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v. Type CPF (2 x 40 W)
Corrosion proof luminaire, cast aluminium control gear housing containing
ballasts, starters, capacitors & terminal block. Structured on seamless heavy
gauge aluminum pipes and cast aluminium end boxes incorporating specially
designed vapour proof lamp holder complete with 2 x 40 W fluorescent tubes.
Dust and weather proof (IP:55) sodium vapour lamp street lighting fixture
comprising of cast aluminium housing accommodating all pre-wired control
gear accessories, white stove enameled from inside deep drawn aluminum
reflector, accommodating lamp holder with clear acrylic cover fixed by means
of four toggles clamps complete with 150 W HPSV lamp.
Flame proof mercury vapour lamp fixture for hazardous areas such as fuel oil
pump house. Thermal shock proof well glass fixed in a canopy. Weatherproof
construction suitable for indoor as well as outdoor. GI wire guard, porcelain
lamp holder, control gear also housed in a heavy gauge gasket, flame proof
enclosure complete with 125 W HPMV lamp.
ii. Distribution system shall be designed for 450C ambient for voltage drop at the
end point limited to 5%.
iii. Distribution Boards / Cabinet shall be located as near as possible to the centre
of the load which they are intended to supply.
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iv. Each out going feeder of the lighting / power socket distribution board shall be
loaded up to 70 to 80% the MCB rating.
v. The current rating of wires connected to the outgoing side of any MCB shall not
be less than the MCB thermal rating. Similarly cables connected to MCCBs
shall have current rating not less than the thermal current rating of its MCCB.
vi. As far as possible load shall be balanced on three phases of each lighting Dist.
cabinet.
vii. Separate MCB and sub-circuits from the LDB shall be utilized for luminaries
and 15A power socket outlets.
viii. Lighting load on individual sub circuit emanating from LDB shall be restricted
to 2 kW.
i. The AC/DC emergency lighting distribution board shall be wall mounted type
sheet metal enclosure similar to the normal LDB in general constructional
features.
ii. It shall have the provision to receive two incoming supplies viz. 240V, 2 wire
AC and 220V, 2 wire DC which shall terminate on a 2 wire, 240V Bus through
MCCBs and changeover AC & DC contactors. Suitable number of outgoing
feeders shall be tapped from the bus through 2 pole MCB of adequate thermal
and short circuit rating.
Provision of at least 20% subjected to minimum of one spare outgoing feeder shall be
kept on each Main Lighting Board and Lighting Distribution Board/ Cabinet.
All buildings/ rooms are to be equipped with 5A and 15 A utility power socket with
individual control supply as required. 15A sockets shall be fed through independent
circuits from the lighting distribution cabinets and that shall installed 250mm above
floor level.
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5.7.14 Welding outlet
A few welding outlets are to be provided in the power plant area as per the system
requirement and these shall be directly feed from 415V switchboard. The welding
outlets shall be of 63 A, 3 phase & neutral controlled by a switch suitable for indoor /
outdoor duty as required. The plug tops shall be supplied loose and handed over
separately.
All three phase welding power outlets shall incorporate a fourth pin for earthing
purpose and shall be fitted with a mechanical interlock which will prevent the plug being
inserted or withdrawn while the switch is in “ON” position.
The bidder shall submit the following drawings/ data after award of contract for
approval :
5.7.16 Standards
5.8 DC SYSTEM
2. Battery:
i. The battery shall be Lead acid (Plante) type or Ni-Cd pocket plate high
discharge (KPH) type.
iii. Battery shall be designed for proper operation and to meet specified load
and their duty cycle under all ambient and site conditions specified
elsewhere.
iv. Number of cells: 220V batteries shall have a minimum of 110 cells each.
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vi. End voltage : End voltage of batteries at the end of duty cycle : not less than
1.85V per cell for Lead-acid and 1.14V per cell for Ni-Cd type.
vii. The bidder shall indicate in their bid the ampere-hour capacity of various
batteries at 10 hour rate of discharge for lead-acid and 5 hour rate of
discharge for Ni-Cd battery at 270C envisaged by them.
ix. Each battery should be provided with suitable moulded case circuit breaker
which shall be located adjoining the battery itself in a separate panel viz.
battery panel. All the MCCBs will have adjustable Short circuit & Overload
settings. The bidder will ensure proper coordinated settings from the
charger board and beyond. All the DC motor feeders will also be provided
with over load alarm. Suitable arrangement shall be provided to annunciate
the tripping of breaker in battery panel as well as at remote control board.
3. Float-cum-Boost Chargers
i The Float (trickle) charger shall have a rating to need float charging load of
the associated battery at the rate of 2 to 2.2V/ Cell for lead-acid and 1.4 to
1.42V/ cell for Ni-Cd and for meeting the constant DC loads to be fed from
the DC system with an overall margin of 10%.
ii. The Boost (quick) charger shall have a rating to meet boost charging load,
equalising charging load of the associated battery at the rate of 1.5 to 2.75V
/ cell for lead-acid and 1.53 to 1.7V/ cell for Ni-Cd and current as
recommended by the battery manufacturer and for simultaneously meeting
the constant DC loads to be fed from the DC system with an overall margin
of 10%. The quick chargers of the battery system shall also be suitable for
routine testing of DC motors connected to the DC system.
iii. The trickle charger and quick charger shall also be capable of meeting
short time impulse loads of the associated DC systems.
iv. DC output voltage variation for trickle chargers and quick chargers shall be
in accordance with requirements of the equipments offered but shall
normally be 210 to 250V and 200 to 320V respectively.
v. The trickle chargers and quick chargers shall be of static type using silicon-
controlled rectifiers with three-phase bridge circuit and ripple factors suiting
the equipment offered but not exceeding 1% pk-pk without battery. This
value of ripple factor shall not affect the performance of electronic and static
equipment supplied by the bidder.
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vi. Each trickle charger shall have an arrangement for automatic and normal
DC voltage regulation with selector switch for mode of operation.
vii Each quick charger shall have normal voltage regulating system.
viii Voltage regulating system for trickle charger and quick charger shall be of
‘static’ type.
ix The automatic voltage regulator of trickle charger shall hold the DC voltage
constant from zero to full load but with a definite drop at load greater than
full load so that such loads are transferred to the battery. The automatic
voltage regulating system shall maintain DC voltage constant to the
requirement of equipment offered but to a voltage not more than +1 % of the
set value for a fluctuation of +10% in voltage and +5% in frequency in the
AC input voltage for purpose of bid.
x. Each trickle charger and each quick charger panel shall be complete with all
necessary equipment and shall be subjected to purchaser’s approval.
xii Facia windows with indicating lamps and inscriptions shall be provided in
each charger panel for annunciations provided in each charger panel shall
at least include the following:
AC supply failure
Battery protection operated
Surge circuit fuse failure
Charger trip
Rectifier fuse failure
Charger load limiter operated
Battery on boost
xiii The transformers associated with trickle chargers and quick chargers shall
be air cooled type.
4. DC Distribution Boards
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Section- 5 (Electrical Works)
The DC motor load shall be fed from separate bus with isolation facility from
the main bus to facilitate testing of motors.
iii Each DC Distribution board shall be provided with (i) earth fault detecting
relays which shall give alarm for earth fault in positive or negative of the
system. (ii) voltage level indicating devices for annunciating ‘DC voltage
low’ and ‘DC voltage high’ with additional initiating contacts for annunciating
the same at control board (iii) voltmeter with selector switch to read voltages
positive to earth, negative to earth and between positive and negative.
v. Each incoming and outgoing feeder shall be provided with magnetic short
circuit protection having adjustable range of pick up current and time delay.
In addition to the above, the feeder breakers for motors shall be provided
with overload protection with suitable range.
i. The boards shall be fully compartmentalized type i.e. each feeder equipment
shall be accommodated in a separate module.
iii. The bus bars shall be of high conductivity aluminium / electrolytic copper of
ample cross section, shall have adequate current rating and shall be without
maximum short circuit stresses. The bus bars shall be insulated and
supported from the structure by means of durable non-hygroscopic, non-
combustible and nontracking material. The entire bus bar system shall be
insulated with PVC sleeves.
6. Tests
The bidder shall carry out all the tests on batteries, battery charger and DC
board as per relevant standards and shall also carry out one hour rate of
discharge test on the batteries. Test reports will be furnished for approval.
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Section- 5 (Electrical Works)
Capacity test on each complete battery at 10hr rate of discharge for Lead acid
battery and 5 hr rate of discharge for Ni-Cd battery shall be carried out at site
after installation.
7. Drawings and Data: The following drawings shall be supplied by the tenderer
with his tender for each battery system.
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Section- 6 (Control & Instrumentation Works)
SECTION 6
6.1 GENERAL
ii) The bidder shall also include in his proposal and shall furnish all
equipment, devices and services which may not be specifically stated in
the specification but are needed for completeness of the
equipment/systems furnished by the bidder and for meeting the intent and
requirements of the specification.
iii) It may be noted that where equipment or system for the unit are described,
same refer to only one set per unit to be furnished by the contractor unless
specifically indicated otherwise. Where equipment or systems for plant
common facilities are described, it will be understood that the quantities
described are the total quantities required.
ii) When more than one device uses the same measurement or control
signal, the transmitter and other components/ module shall be fully
equipped to provide all signal requirements. The system shall be arranged
so that the failure of any monitoring device or control components or
spurious intermediate grounding in the signal path shall not open the
signal loop nor cause the loss or malfunction of signal to other devices
using the same signal.
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Section- 6 (Control & Instrumentation Works)
The types of failure which shall be taken into account for ensuring
operability of the plant shall include but not be limited to:
ii) The choice of hardware shall also take into account sound
maintainability principles and techniques. The same shall include but
shall not be limited to the following:
a) Standardization of parts.
b) Minimum use of special tools.
c) Grouping of functions.
d) Interchangeability.
e) Malfunction identification facility/self surveillance facility.
f) Easy modular replacement.
g) Fool proof design providing proper identification and other features
to preclude improper mounting and installation.
h) Appropriate derating of electronic components and parts.
iii) The equipment shall employ latest state of the art technology to guard
against obsolescence. In any case, bidder shall be required to ensure
supply of spare parts for 15 years of the plant. In case, it is felt by the
Bidder that certain equipment/component is likely to become obsolete,
the Bidder shall clearly bring out the same in his bid and indicate steps
proposed to deal with such obsolescence.
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Section- 6 (Control & Instrumentation Works)
PLC system based control, monitoring & operation shall be provided for the
flue gas desulphurization (FGD) system. Further, the FGD PLC shall be
provided with soft link for collection of data in the DDCMIS (In Purchaser's
scope) for the information of unit-incharge / shift-incharge etc. through Station
Wide LAN. All required interfacing hardware and software shall be provided
by bidder.
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Section- 6 (Control & Instrumentation Works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 6 (Control & Instrumentation Works)
a) Receiving binary and analog signals from the field and operator
initiated commands from OWS/ control panel.
ii) The controller shall provide all basic functions for binary gating
operations, modulating controls, storage, counting, timing, logging,
transfer operations and comparison functions.
iii) Each PLC unit shall be provided with two processors (Main processing
unit and memories) one for normal operation and one as hot standby. In
case of failure of working processor, there shall be an appropriate alarm
and simultaneously the hot standby processor shall take over the
complete plant operation automatically. The transfer from main
processor to standby processor shall be totally bumpless and shall not
cause any plant disturbance whatsoever. In the event of both processors
failing, the system shall revert to fail safe mode. It shall be possible to
keep any of the processors as master and other as standby. The standby
processor shall be updated in line with the changes made in working
processor. Power supply unit shall be hot redundant for each CPU & I/O
rack.
iv) The memory shall be field expandable. The memory capacity shall be
sufficient for the complete system operation and have a capability for at
least 20% expansion in future. Programmed operating sequences and
criteria shall be stored in non volatile semiconductor memories like
EPROM. All dynamic memories shall be provided with buffer battery
backup which shall be for at least 360 hours. The batteries shall be
lithium or Ni-Cd type.
v) The OWS shall perform control, monitoring and operation of all
auxiliaries/ drives interacting with PLC based control system. It shall
basically perform the following functions:
a) Operator interface for PLC based control system. Operator
functions shall as minimum include local/ remote selection, A/M
selection, open/ close operation, sequence auto, start/ stop
selection, ON/OFF, bypassing criteria etc.
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Section- 6 (Control & Instrumentation Works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 6 (Control & Instrumentation Works)
6.2.3.1 General
i) Operator work station (OWS) shall perform control, monitoring and
operation of all auxiliaries/ drives interacting with PLC based control
system. It shall be possible to use the same as programming station of
the PLC and the Human Machine Interface System. It shall basically
perform the following functions. In case the PC based OWS cannot be
used as programming station of the PLC and the Human Machine
Interface System, then separate PC based programming station shall
be provided.
iii) All frequently called important functions including major displays shall
be assigned to dedicated function keys on a soft keyboard for the
convenience of the operator for quick access to displays & other
operator functions.
iv) The operator functions for each OWS shall as a minimum include
Control System operation (A/M selection, raise/lower, set point/bias
change, on/off, open/close operation, mode/device selection,
bypassing criteria, sequence auto, start/stop selection, drive auto
selection, local-remote/other multi-position selection etc.); alarm
acknowledge; call all kind of displays, logs, summaries, calculation
results, etc.; printing of logs & reports; retrieval of historical data; and
any other functions required for smooth operation, control &
management of information as finalized during detailed engineering.
vi) The system shall have built-in safety features that will allow/disallow
certain functions and entry fields within a function to be under password
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Section- 6 (Control & Instrumentation Works)
vii) When any drive or sequence is being controlled from one OWS, the
system shall inhibit control access of the same drive or sequence from
other OWS or Local Control Panel.
4 Monitor (colour) LED based 24” sized LED based 24” sized
Monitors. with non- Monitors. with non-
interfaced refresh rate interfaced refresh rate
min. 75 Hz. Full HD min. 75 Hz. Full HD
resolution 1920 X 1080, resolution 1920 X
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Section- 6 (Control & Instrumentation Works)
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Section- 6 (Control & Instrumentation Works)
software - to suit
project specific
requirement.
15 Additional Comprehensive disk Comprehensive disk
general maintenance utility for maintenance utility for
purpose software disk clean sweep/ crash disk clean sweep/
(for using over guard/ antivirus, etc. (like crash guard/ antivirus,
network by "Norton System Works") etc. (like "Norton
servers/ System Works")
workstations
PCs)
6.2.3.3 Laptop
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 6 (Control & Instrumentation Works)
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Section- 6 (Control & Instrumentation Works)
e) The design and installation of the system bus shall take care of the
environmental conditions as applicable.
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Section- 6 (Control & Instrumentation Works)
The Contractor shall furnish details regarding the communication system like
communication protocol, bus utilisation calculations etc.
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Section- 6 (Control & Instrumentation Works)
vii) The control system hardware design shall be such that it is able to
withstand power line disturbances as per relevant standard.
viii) Functional grouping of various controllers shall be decided during
detailed engineering which shall be subject to purchaser's approval. For
each of the functional groups, separate sets of controllers, I/O modules,
communication controllers, power packs/ modules etc. shall be provided.
Mixing of hardware of two or more functional groups (FG) shall not be
acceptable.
i) The OLCS shall include sequence control, interlock & protection for
various plant auxiliaries, valves, dampers, drives etc. The sequence
control shall provide safe and automatic startup and shutdown of plant
and of plant items associated with a plant group. The interlock and
protection system shall ensure safe operation of plant/plant items at all
times and shall automatically shut down plant/plant items when unsafe
conditions arise.
ii) The OLCS shall be arranged in the hierarchical control structure
consisting of unit level, group level, subgroup level & drive level (as
applicable).
iii) It shall be possible to perform automatic unit startup & shutdown by
issuing minimum number of command from the OWS. Thus, the unit level
shall control all the control system blocks and issue appropriate startup
and shutdown commands to various blocks of control system.
iv) The group level shall control a set of functional sub-groups of drives.
Appropriate start-up and shut down commands shall be issued to the sub-
group control and various check backs shall be received from sub-groups
or drives. Each sub-group shall execute the sequential start-up and shut
down programmes of a set of inter-related drives along with system
interlocks and protections associated with that sub-group as well as basic
interlocks and protections related to individual drive falling under that sub-
group. The drive level shall accept commands from the sub-groups, push
buttons (wherever provided), etc., and transmit them to the respective
drive, after taking into account various interlocks and protections and the
safety of that particular drive.
v) A sequence shall be used to move a set of groups and sub-groups from
an initial steady state (for instance 'OFF') to a final steady state (for
instance 'ON'). The sequence initiating command for the unit and group
level shall be issued from OWS.
vi) A sequence shall be made of steps. The steps shall be executed in
predetermined order according to logic criteria and monitoring time
consisting of the interlock & protection requirements and check back of
previous step which shall act as pre-conditions before the sequence
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 6 (Control & Instrumentation Works)
iii) The control loop shall have enough flexibility and various features to
perform feed forwards, balancing of controller, increasing the response
to achieve the desired process parameter within prescribed time frame.
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Section- 6 (Control & Instrumentation Works)
v) Any switch over from auto to manual, manual to auto and switchover
from OWS operation to auto manual station operation and vice versa
shall be bumpless and without resulting in any change in the plant
regulations and the same shall be reported to the operator.
vii) The system being supplied shall be such that when permissible limits
are exceeded, an automatic switchover from an operation governed by
maximum efficiency, to an operation governed by safety and availability
is affected.
viii) For safety reasons, switchover logics associated with the modulating
control loops, shall be performed within the closed loop control
equipment. Modulating control loops shall be provided with standard
features to interface overriding commands from OLCS/Protection
System like open, protection open etc.
ix) Time supervision facility shall be provided to monitor the final control
element.
xi) All controllers shall be freely configurable with respect to requisite control
algorithms.
i) Input used for protection shall be dual redundant. Each of the redundant
binary & analog inputs shall be wired to separate input modules. These
redundant modules shall be placed in different racks, which will have
separately fused power supply distribution. Implementation of multiple
measurement scheme of these inputs will be performed in the
redundant hardware. Loss of one input module shall not affect the
signal to other modules. Other channels of these modules can be used
by other inputs of the same functional group.
ii) The single binary and analog signals required for control purposes shall
be wired as follows:
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Section- 6 (Control & Instrumentation Works)
a) The limit & torque switches and the MCC/ Swgr check backs shall be
wired to drive control modules wherever provided. For the drives
where drive control modules are not provided, these signals shall be
connected to input module only.
b) Other single analog & binary inputs shall be wired to single input
modules. The on-off status of HT drives etc., however, be wired to
two input modules in parallel.
iii) Inputs and outputs related to each of the redundant drives / equipment
(e.g. each of the 3x50 % drives, each of the storage vessel/sump/tank
storing same fluid, each of the streams and its related drives etc.) shall
be wired to separate input and output modules.
6.2.6.5 The signal conditioning functions like multiple measurement schemes, square
root extraction for flow signals, pressure and temperature compensation, limit
value computation can be performed either in the controllers or in signal
conditioning and processing hardware outside controllers.
Further, minimum 10% spare channels shall be kept for each type of the
input/output modules.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
- Ladder diagram
Even under worst case loading condition of HMIS and system Bus, each HMIS
processor shall have 50 % spare time when measured over any one minute
period and the system bus shall have at least 50 % spare duty cycle.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
i) The cabinets shall be IP-32 protection class. The Contractor shall ensure
that the packaging density of equipment in these cabinets is not
excessive and abnormal temperature rise, above the cabinet tempera-
ture during normal operation or air-conditioning failure, is prevented by
careful design. This shall be demonstrated to the Purchaser during the
factory testing of the system. The Contractor shall ensure that the
temperature rise is limited to 10 deg. C above ambient and is well within
the safe limits for system components even under the worst condition as
specified in Sub-section-basic Design criteria and specification
requirements for remote I/O cabinets.
Ventilation blowers shall be furnished as required by the equipment
design and shall be sound proof to the maximum feasible extent. If
blowers are required for satisfactory system operation, dual blowers with
blower failure alarm shall be provided in each cabinet with proper
enclosure and details shall be furnished with proposal. Suitable louvers
with wire mesh shall be provided on the cabinet.
ii) The cabinets shall be designed for front access to system modules and
rear access to wiring and shall be designed for bottom entry of the
cables.
iii) The cabinets shall be totally enclosed, free standing type and shall be
constructed with minimum 2 mm thick steel plate frame and 1.6 mm thick
CRCA steel sheet or as per supplier's standard practice for similar
applications, preferred height of the cabinet is 2200 mm. The cabinets
shall be equipped with full height front and rear doors. The floor mounting
arrangement for other cabinets shall be as required by the Purchaser
and shall be furnished by the Contractor during detailed engineering.
iv) Cabinet doors shall be hinged and shall have turned back edges and
additional braking where required ensuring rigidity. Hinges shall be of
concealed type. Door latches shall be of four-point type to assure tight
closing. Detachable lifting eyes or angles shall be furnished at the top of
each separately shipped section and all necessary provisions shall be
made to facilitate handling without damage. Front and rear doors shall
be provided with locking arrangements with a master key for all cabinets.
If width of a cabinet is more than 800 mm, double doors shall be
provided.
v) Two spray coats of inhibitive epoxy primer-surface shall be applied to all
exterior and interior surfaces. A minimum of 2 spray coats of final finish
colour shall be applied to all surfaces. The final finished thickness of
paint film on steel shall not be less than 65-75 micron for sheet thickness
of 2 mm and 50 microns for sheet thickness of 1.6 mm. The finish colors
for exterior and interior surfaces shall conform to following shades:
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
i) The HSRS shall collect, store and process system data from MMIPIS
data base. The data shall be saved online on hard disk and
automatically transferred to erasable long term storage media once in
every 24 hours periodically for long term storage. Provision shall be
made to notify the operator when hard disk is certain percentage full.
The disk capacity shall be sufficient to store at least seven days data.
ii) The data to be stored in the above system shall include alarm and event
list, periodic plant data, selected logs/reports. The data/information to
be stored & frequency of storage and retrieval shall be as finalised
during detailed engineering. The system shall provide user-friendly
operator functions to retrieve the data from historical storage. It shall
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
iii) In addition to above, the system shall also have facility to store &
retrieve important plant data for a very long duration (plant life) on
portable long term storage media). These data will include any data
from the database as well as processed/computed data based various
calculations/ transformation. The retrieved data from long term storage
media should be possible to be presented in form of alarms, logs,
reports etc.
6.2.9 Printer
One number A4 size color laser printer and one number A3 sized dot matrix
printer shall be provided as a part of the supervisory system. It shall print out
all alarm/trip conditions and event changes in plant status along with date and
time of occurrence. 5 set of print cartridges shall be provided with each type of
printer.
6.2.10 Furniture
Bidder shall provide following industrial grade furniture items as a minimum
from reputed manufacturers/suppliers meeting International Standards. The
furniture shall be modular and latest with ease of operational features. The
furniture shall be modern, aesthetically designed, modular, flexible, space
saving and future safe. Each module shall have transparent cover and
adjustable partition. It shall have locking provision for security. The
components shall be suitable for integration/fabrication without any welding
technology.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
iv) Chairs
Industry standard revolving chairs with wheels and with provision for
adjustment of height (hydraulically/gas lift) shall be provided for the
operators, unit-in-charge, shift in charge & other personnel in control
room area & other rooms etc. These shall be designed for sitting for long
duration such that these are comfortable for the back. Chair pedestal
shall be made of 5mm thick MS plate covered with poly-propylene
cladding. Arm-rests in one piece shall be of poly-urethane and twin
wheel castor of glass filled nylon. The exact details shall be finalised &
approved by Purchaser during detailed engineering.
v) Tables
Industry standard computer tables shall be provided & shall be as
approved by Owner during detailed Engineering.
vi) Almirahs
Minimum 4 nos. vertical Steel Almirahs shall be provided for keeping
documents etc. Final quantity shall be decided by owner during detailed
engineering.
vii) Keypad
Keypads shall be provided for the storing of keys of relevant
areas in the respective control rooms
viii) Lockers
Suitable lockers shall be provided in the room adjacent to the control
room for storing of personal articles of control room personnel & also
for documents.
6.2.11 Software Documentation and Software Listings
i) All technical manuals, reference manuals, user’s guide etc., in English
required for modification/editing/addition/deletion of features in the
software of the PLC System shall be furnished. The Contractor shall
furnish a comprehensive list of all system/application software
documentation after system finalisation for Purchaser’s review and
approval.
ii) All The software listings including Source code for application software,
All special-to-project data files etc. shall be submitted by the Contractor:
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
6.3.1 General
ii) Every panel mounted instrument requiring power supply shall be provided
with a pair of easily replaceable glass cartridge fuses of suitable rating.
Every instrument shall be provided with a grounding terminal and shall be
suitably connected to the panel grounding bus.
iii) All local gauges as well as transmitters, sensors, and switches for
parameters like pressure, temperature, level, flow etc. and vibration
transmitters as required for the safe and efficient operation and
maintenance as well as for operator and management information
(including all computation) of equipment under the scope of specification
shall be provided. In general, transmitters shall be provided for all the
cases, instead of switches. Use of processor actuated switches shall be
avoided and shall be acceptable only where the same is as per
manufacturer’s standard & proven factors.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
iv) Vibration transmitters with 4-20 mA signals hard wired to FGD PLC shall
be provided for all critical HT drives.
vi) All field instruments shall be weatherproof, drip tight, dust tight and splash
proof suitable for use under outdoor ambient conditions prevalent in the
subject plant. All field-mounted instruments shall be mounted in suitable
locations where maximum accessibility for maintenance is achieved. The
enclosures of all electronic instruments shall conform to IP-65 unless
otherwise specified.
vii) For all instruments envisaged for corrosive liquid applications, they shall
be provided with wetted parts made of Monel / Hastelloy C or any other
material (if provenness experience of the proposed material for such
applications is established by Contractor).
viii) All instruments shall be provided with durable epoxy coating for housings
and all exposed surfaces of the instruments.
ix) All field instruments shall be weatherproof, drip tight, dust tight and splash
proof suitable for use under outdoor ambient conditions prevalent in the
subject plant and shall be mounted in suitable locations where maximum
accessibility for maintenance is achieved. The enclosures of all electronic
instruments shall conform to IP-65 unless otherwise specified (Explosion
proof for NEC article 500, class 1/2, Division 1 area & Flame proof area)
and an anti corrosive paint shall be applied to the field mounted
enclosures/ instruments.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
7. Zero and span drift ± 0.015% per deg. C at max span and
0.11% per deg. C at min. span.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
Notes:
(i) Length of gauge glass shall not be more than 1400 mm. If the
vessel is higher, multiple gauge glasses with 50 mm overlapping
shall be provided.
(ii) Where the process fluids are corrosive, viscous, solid bearing or
slurry type, diaphragm seals shall be provided. Parts below the
diaphragm shall be removable for cleaning. The entire volume
above the diapragm shall be completely filled with an inert liquid
suitable for the application.
(iii) Float & Board type level gauges may also be acceptable as per
process requirement subject to approval of purchaser.
Guided wave radar type level transmitters shall be provided for level
measurements of the vessel under vacuum or low pressure applications.
Type Guided wave Radar
Principle TDR (Time domain reflectrometry)
Probe Type & Material Coaxial, SS316/316L. If required, probe
shall be suitable for overfill prevention.
Connection type and material Flanged and SS316/316L.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
The transmitters shall be provided with IP-65 protection class with durable
corrosion resistant coating.
The transmitters shall be able to provide digital signals super imposed on 4-
20 mA signal as per HART protocol.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
type calibrator is not suitable for communicating with all types of transmitters
then separate hand held calibrator will be provided.
HART hand held calibrator shall be provided with following minimum
accessories per set:-
i) Soft carrying case with adjustable shoulder straps & lead
compartments.
ii) HART lead set.
iii) Rechargeable batteries.
iv) Battery charger.
v) Power adaptor.
vi) Universal plug kit for power adaptor.
vii) Load resistor.
viii) Interfacing cables of each type as per requirements.
ix) Protective boot.
x) Standard banana jack.
xi) Operation manual & software CD.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
iii) Thermowell
(a) Shall be one piece solid bored type of 316 SS material or better (as per
process requirement), of step-less tapered design. (As per ASME PTC
19.3 (Latest).
(b) For Air & Flue gas, 316 SS protecting tube with welded cap shall be
provided.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
61326
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
System
etc.
types:
i) Orifice plate
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
iii) Rotameters
Materials
Body : Carbon steel/SS316 as per process
requirement
Gaskets : Neoprene
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
Notes:-
1) Where the process fluids are corrosive, viscous, solid bearing or slurry
type, diaphragm seals shall be provided. Parts below the diaphragm shall
be removable for cleaning. The entire volume above the diaphragm shall
be completely filled with an inert liquid suitable for the application.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
Mounting : On Top
6.3.10 Analysers
Technical specification for SO2 analysers shall be as specified in Cl. No. 6.8.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
6.3.10.2 pH Analyser
1. Type 2/3/4 way with body material of SS 316/Forged Brass and epoxy
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
i) The actuators shall have integral starters alongwith overload relays with
built in SPP (single phasing preventer). A 415, 3 phase 3 wire power
supply shall be given to the actuator from contractor’s switch board
through a switch fuse unit. Control voltage of the motor starter shall be
110 V AC / 24 V DC, derived suitably from 415V power supply. In case
supplier's standard control voltage for open/close contactors is 110V AC,
the same is acceptable if suitable up to - isolation circuit is provided with
coupling relays for 24 V DC command inputs.
ii) Open/close command termination logic with position and torque limit
switches, positioner circuit shall be suitably built in the PCB inside the
actuator.
(a) For binary drive, open/close command and status thereof and
disturbance monitoring signal (common contact for overload,
thermostat, control supply failure, L/R selector switch at local,
other protections operated) shall be provided.
iii) The actuators shall be rated for supply voltage & frequency: 415V +/-
10%, 3- phase, 3 wire 50Hz +/-5%. Sizing for open/close at rated speed
against designed differential pressure at 90% of rated voltage. For
isolating service, three successive open-close operations or 15 mins,
whichever is higher. For regulating service, 150 starts per hour or
required cycles, whichever is higher.
iv) Four nos. (2 each in open and close position) position limit switches and
two nos. (one in open and other in close direction) torque switches each
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
ix) Space heater of suitable rating shall be provided. The supply shall be
derived from the main power supply available in the actuator.
Pull chord type (manually reset type) emergency stop switches shall be
located on both sides of belt conveyors along the walkways for the
entire length of conveyors for emergency stopping of conveyor. The
enclosure shall be of cast aluminum with degree of protection IP-65.
Local pull chord actuation shall be provided by means of mechanical
flap. Each switch shall have two NO and two NC contacts, which shall
be wired out to the terminal block. The terminal block shall have
facilities of cable looping. Adequate length of rope and all accessories
shall be furnished.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
6.3.13.5 One number Trip indicator panel per conveyor, which shall display the exact
number of safety switches (pull cord or belt sway switches) operated in a
loop of conveyor considering 10% spare switches shall also be provided. It
shall also monitor the condition of field cable connecting the switches in
series & generate signal, if field cable is found broken or short. LCD display
shall be provided with each trip indicator for details like fault location, fault
indication, etc. Each event/trip shall be recorded in the trip indicator and
PLC.
i) General Requirements
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
b) All the control valves and accessories offered by the Bidder, shall
be from reputed, experienced manufacturers of specified type and
range of valves.
a) All valves shall be of globe body design & straightaway pattern with
single or double port unless otherwise specified or as recommended
by the manufacturer as per process requirement. Rotary valve may
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
b) Valves with high lift cage guided plugs & quick change trims shall be
supplied in case of globe type valves.
d) Bonnet joints for all control valves shall be of the flanged and bolted
type or other construction acceptable to the Purchaser. Bonnet joints
of the internal threaded or union type will not be acceptable.
v) Valve Materials
The control valve body & trim material shall be generally as given below:
Note : Valve body rating shall meet the process pressure and
temperature requirement as per ANSI B16.34.
However, Bidder may offer valves with body and trim materials better
than specified materials.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
ends wherever required shall be butt welded type as per ANSI B 16.25
for control valves of sizes 65 mm and above. For valves size 50 mm
and below welded ends shall be socket welded as per ANSI B 16.11
Flanged ends wherever required shall be of ANSI pressure-temperature
class equal to or greater than that of control valve body.
ii) Hydrostatic shell test in accordance with ANSI B 16.34 prior to seat
leakage test.
iii) Valve closure test and seat leakage test in accordance with ANSI- B
16.34 and as per the leakage class.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
iv) Functional test: The fully assembled valves including actuators control
devices and accessories shall be functionally tested to demonstrate
times from open to close position.
v) CV test: CV test shall be carried out as type test on each size, type
and design of the valves as per ISA 75.02 standard and test report shall
be furnished for Purchaser’s approval (if valid type test is not available).
The UPS system shall have 2x100% parallel redundant chargers and inverters,
1x100% battery bank, bypass line transformers and voltage stabiliser, static
switch, manual bypass switch, AC/DC distribution boards, other necessary
protective devices and accessories and shall meet the following requirements
as a minimum.
i) The kVA rating of UPS shall be as required by expected loads and include
10% spare capacity guaranteed at 50 deg C ambient. The UPS shall have
an over load capacity of 125 % rated capacity for 10 minutes and 150 %
rated capacity for 10 seconds. The inverter shall have sufficient capability
to clear fault in the maximum rated branch circuit. The sizing of UPS shall
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
be based on the power factor of the loads being fed subject to a maximum
of 0.8.
ii) Each of the two sets of 2x100% redundant chargers shall be sized to meet
the 100% UPS load plus recharge the fully discharged battery within 8
hours.
iii) The UPS battery shall have sufficient amp-hour capacity to supply 100%
full load current of UPS for 60 minutes. A drop of 4V from battery room to
the inverter input will be considered for design.
iv) The UPS system shall be capable of operating without D.C. battery in
circuit under all conditions of load and the performance of various
components of UPS like inverter, charger, static switch etc. shall be
guaranteed without the battery in circuit.
vi) The UPS system design shall ensure that in case of failure of mains input
power supply to one of the chargers, the other charger whose mains input
power supply is healthy, shall feed to one or both the inverters as the case
may be as per manufacturer's standard practice & continue to charge the
D.C. battery at all load conditions. The Bidder should note that this
situation should not in any way lead to the discharge of the D.C. Battery.
6.5.3 Static Inverters
i) The static inverter shall be solid state type using proven pulse width
modulation (PWM)/quasi square wave/step wave technique. The inverter
equipment shall include all necessary circuitry and devices to conform to
requirements like voltage regulation, current limiting, wave shaping,
transient recovery, automatic synchronization etc. The steady state voltage
regulation shall be +1% and transient voltage regulation (on
application/removal of 100% load) shall be +20%. Time to recover from
transient to normal voltage shall not be more than 50 m sec. Frequency
regulation for all conditions of input supplies, loads and temperature
occurring simultaneously or in any combination shall be better than ± 0.5%
(automatically controlled). The total harmonic content shall be 5%
maximum and content of any single harmonic shall be 3% maximum. The
inverter efficiency shall be at least 85% on full load and 80% on 50% load.
The synchronisation limit for maintenance of synchronisation between the
inverter and standby AC source shall be 48-52Hz, field adjustable in steps
of 0.5 Hz.
ii) All necessary equipment shall be provided to protect the inverter against
overload, short circuit and 100% loss of load.
iii) Inverter equipment shall include all solid state circuitry and devices
including stable oscillator etc. to enable inverters to operate satisfactorily
in parallel sharing mode each inverter taking 50% load during normal
operation. In case of failure of either inverter, 100% load shall automatically
be transferred to healthy inverter without any break and degradation in the
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
The static switch shall be provided to perform the function of transferring UPS
loads automatically without any break from (i) faulty inverter to standby AC
source in case of failure of both the inverters and (ii) from faulty inverter to
standby AC source in case of failure of both the inverters. Manual bypass switch
shall be employed for isolating the UPS during maintenance.
The transformer shall be of low impedance type and the rating shall be such
that extremely fast fault clearance is achieved even in the largest rated branch
circuit. The overload capacity of the transformer/stabilizer shall not be less than
300% for 200 ms. The stabilizer shall employ silicon solid state circuitry and the
output voltage regulation shall be ± 2%. The efficiency of the stabiliser shall be
95% or better.
The details of the AC distribution board, i.e. exact design, number of feeders
etc. of the 2x100% ACDB shall be as finalised during detailed engineering and
as approved by the purchaser. However, 25% spare feeders (minimum one no.)
with fuses for each rating shall be provided.
6.5.7 The UPS, system equipment and the complete system shall have surge
withstanding capability (SWC) to meet the requirements of ANSI C 37.90a –
IEEE Standard 472 –1974. UPS should be provided with Class C type surge
protection device. The Class C type surge arrester should be single MOV type,
pluggable, should have fault indication and should be tested as per IEC 61643-
1 to withstand 40kA 8/20 µs pulse. The arresters should have potential free
contact to ensure maintainability.
6.5.8 One complete set of all accessories and devices required for maintenance and
testing of batteries shall be supplied and same shall include at least the
following :
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
1 Hydrometer 5 Nos.
2 Set of hydrometer syringes suitable for the vent 5 Nos.
holes in different cells
3 Thermometer for measuring electrolyte temperature 5 Nos.
4 Specific gravity correction chart 5 Nos.
5 Wall mounting type holder made of teak wood for 5 Nos.
hydrometer & thermometer
6 Cell testing voltmeter (3-0-3 V) 5 Nos.
Alkali mixing jar 5 Nos.
7
8 Rubber apron 5 Nos.
9 Pair of rubber gloves 5 Nos.
10 Set of spanners 5 Nos.
11 No smoking notice for each battery room 2 Nos.
12 Goggles (industrial) 5 Nos.
13 Instruction card 10 Nos.
14 Minimum and maximum temperature indicator for 1 set
battery room
15 Cell lifting facility 1 No.
Two tier battery racks made of steel and painted with anti- corrosive epoxy paint
construction in accordance with applicable codes and standard shall be
provided. AISC specification shall apply in the absence of another design
specification.
6.6 PROCESS CONNECTION PIPING
The bidder shall provide, install and test all required material for completeness
of impulse piping system, sample piping system and air piping system as per
the requirements for the connection of instruments and control equipment to
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
the process and make the system complete. The bidder shall furnish during
detailed engineering all relevant drawings, material and technical specifications
of various items service wise for Purchaser's approval.
All materials supplied shall be suitable for intended service, process, operating
conditions and type of instruments used and shall fully conform to the
requirements of this specification. The material offered by the bidder shall be
from reputed, proven manufacturer.
ii) Stainless steel tube shall be provided inside enclosures and racks from
tee connection to valve manifold and then to instrument. The material
shall be ASTM A 213 TP 316L.
iii) All fittings shall be forged steel and shall conform to ANSI B16.11. The
material of forged tube fittings for shaped application (e.g. tee, elbow
etc.) shall be ASTM A182 Gr. 316 H for high pressure/ temperature
applications and ASTM A182 Gr. 316L for other applications. The
material for bar stock tube fitting (for straight application) shall be 316
SS. Metal thickness in the fittings shall be adequate to provide actual
bursting strength equal to or greater than those of the impulse pipe or
SS tube, with which they are to be used.
iv) The source shut-off (primary process root valve) and blow down valve
shall be of 1/2 inch size globe valve type for all applications except for
air and flue gas service wherein the source shut-off valve shall be 3/4
inch size gate valve to avoid frequent chocking. The disc and seat ring
materials of carbon steel and alloy steel valves shall be ASTM A-105
and ASTM A-182, Gr. F22, hard faced with stellite (minimum hardness -
350 BHN.) The surface finish of 16 RMS or greater is required in the area
of stem packing. The valve design shall be such that the seats can be
re-conditioned and stem and disc may be replaced without removing the
valve body from the line.
v) The valve manifolds shall be of 316 stainless steel with pressure rating
suitable for intended application.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 6 (Control & Instrumentation Works)
ii) All fittings shall be socket welding type and of material ASTMA182
F316H conforming to ANSI B 16.11.
iii) Single and multi tubes shall run with the minimum number of changes in
direction. Suitable identification tags shall be provided for easy checkup
and for proper connections.
iv) The valves to be used in sample piping shall be of globe type, forged
construction and stainless steel conforming to ASTM A182. The
pressure and temperature ratings shall be as per ANSI B16.34. The
valve design shall be such that the seats can be re-conditioned and stem
and disc can be replaced without removing valve body from the line.
i) All pneumatic piping, fittings, valves, air filter cum regulator and other
accessories required for instrument air for the various pneumatic
devices/ instruments shall be provided.
ii) For individual supply line and control signal line to control valve, 1/4 inch
size light drawn tempered copper tubing conforming to ASTM B75 shall
be used. The thickness of copper tubing shall not be less than 0.065
inch and shall be PVC coated. The fittings to be used with copper tubes
shall be of cast brass, screwed type.
iii) All other air supply lines of 1/2 inch to 2 inch shall be of carbon steel hot
dipped galvanized inside and outside as per IS-1239, heavy duty with
threaded ends. The threads shall be as per ASA B.2.1. Fittings material
shall be of forged carbon steel A234 Gr. WPB galvanized inside and
outside, screwed as per ASA B2.1. Dimensions of fittings shall be as per
ASA B16.11 of rating 3000 lbs.
iv) For air supply to various devices mentioned above, the bidder shall
provide 2 inch size GI pipe header(s) with isolation valve. From 2 inch
header, 1 inch sub-header(s) shall be branched off at required locations
with isolation valve. From 1 inch sub-header, branch line of 1/2 inch, with
isolation valve shall be provided up to various devices. Similar system is
to be followed for service air required for intermittent purging in the Local
Instrument Enclosures (LIEs) etc.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
v) Instrument air filter cum regulator set with mounting accessories shall be
provided for each pneumatic device requiring air supply. The filter
regulators shall be suitable for 10 kg/ sq.cm max. inlet pressure. The
filter shall be of size 5 microns and of material sintered bronze. The air
set shall have 2 inch size pressure gauge and built in filter housing
blowdown valve.
vi) All the isolation valves in the air supply line shall be gate valves as per
ASTM B62 inside screw rising stem, screwed female ends as per ASA
B2.1. Valve bonnet shall be union type & trim material shall be stainless
steel, body rating 150 pounds ASA. The valve sizes shall be 1/2 inch to
2 inch.
vii) Purge Air Connection for Air and Flue Gas Applications
a) The continuous purging with instrument air shall be done, for all air
and flue gas measurements excepting instrument air and service air
instruments, at the process source connection end. Necessary
arrangements required for continuous purging shall be provided
inside all the air and flue gas enclosures.
i) For steam and liquid measurements, the impulse pipe should preferably
slope downwards from source connection to instrument and instrument
shall be installed below the source point. If due to any reason instrument
is installed above the source point, the impulse pipe should slope
upwards continuously and a 'pigtail' should be provided at the instrument
to assure a water seal for temperature protection. For vacuum
measurements instrument shall be installed above source point and
impulse pipe should slope upwards.
ii) Impulse piping for air and flue gas shall slope upwards and instrument
shall be installed above source point. If this requirement cannot be met
special venting or drain provision shall be provided with vent and drain
lines along with isolation valves and other accessories including drain
pipes. This drain is to be connected to plant drain through open funnel
also.
iii) All impulse piping shall be installed to permit free movement due to
thermal expansion. Wherever required, expansion loops shall be
provided. Expansion joints shall be provided wherever required.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
iv) Colour coding of all impulse pipes shall be done by the bidder in line with
the colour coding being followed for the parent pipes.
Instrument air and service air headers and their branches with all associated
fittings and accessories shall be provided for giving supply to all consumers, as
per the requirements. Air piping shall be installed always with a slope of over
1/100 to prevent accumulation of water within the pipe.
Single and multi tubes shall run with the minimum number of changes in
direction. Suitable identification tags shall be provided for easy checkup and for
connections.
i) General Requirements
The equipment and work performed shall be subject to shop and site test
as per approved quality assurance plan.
All air headers & branch pipes shall be air tested by pressure decay
method as per ANSI B31.1. Flexible hoses and short signal tubing shall
be tested at normal pressure for leakage. Long signal tubing shall be
244
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
tested by charging each tube with air at 2 kg/ sq. cm. through a bubbler
sight glass.
6.7 FGD CONTROL DESK, SYSTEM CABINETS, LOCAL PANELS & TRANSMITTERS
ENCLOSURES/ RACKS
6.7.1 General
i) All control desks, panels, system cabinets, local panels and local
instrument enclosures, racks shall be furnished fully wired with
necessary provision for convenience outlets, internal lighting, grounding,
ventilation, space heating, anti-vibration pads, internal piping and
accessories as per IS:5039-1969 as required for completeness of the
system.
ii) All panels, desks, cabinets shall be free standing type and have bottom
entry for cables unless otherwise specified. The bottom of desks, panels,
cabinets, enclosures shall be sealed with bottom plate, compression
cable glands and fire proof sealing material to prevent ingress of dust
and propagation of fire.
iii) All electronic system cabinets shall be designed for 50 deg C operating
under maximum ambient temperature without air conditioning system in
service. Further cabinets, panels shall be so designed that temperature
rise due to heat load does not exceed 10 deg. C above ambient
temperature under all operating conditions. Necessary louvers, fans,
limited packing density, adequate spacing between instruments, devices
etc. shall be provided to maintain temperature rise within permissible
limits.
iv) Desk, panels, cabinets enclosures wiring and piping shall be arranged
to enable the removal of instruments and devices without unduly
disturbing them.
v) All panels, desks, enclosures interiors shall be illuminated with rapid start
fluorescent strip fixtures with door actuated switches. Door switch
terminals shall be shrouded. All illuminated lights shall be provided with
individual switch in parallel with door switch.
vi) All panels, desks, cabinets shall be properly grounded. The grounding
scheme shall be as approved by the purchaser.
vii) Exterior steel surface shall be sand blasted, ground smooth, filled,
primed, sanded and smooth enamel painted to give a good finish subject
to minimum paint thickness of 65-75 microns for sheet thickness of 3 mm
and 50 microns for sheet thickness of 2mm. Minimum 2 coats of primer
and two sprays of final finish colour shall be applied to all surfaces.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
i) FGD control desk shall be free standing table top type with doors at the
back and shall be constructed of 3 mm thick CRCA steel plates. All
operators TFTs & keyboards shall be mounted on this desk. PA system
hand-sets, telephone sets shall also be mounted. Very few auto-manual
stations & PB stations and lamps may also be mounted on the control
desk, if found necessary. The desk shall be arranged in an continuous
arc shape. The exact profile of the desk, dimension and the radius of
curvature shall also be finalised during detailed engineering stage.
iii) The bidder must pay particular attention in the positioning of desk
mounted OWS in relation to control room lighting in order to minimise
reflections.
iv) For panels, desks mounted instruments/ devices, etc. which are to be
powered from UPS, all required conversion of interface equipment,
accessories to make such devices compatible with UPS supply shall be
provided. All necessary hardware like input switches, fuse unit for each
feeder as well as switch fuse unit for each instrument/ device on the
power supply line shall be provided. From UPS, two feeders shall be
provided along with suitably rated MCB and provision of fast auto
changeover of UPS feeders. Power supply distribution scheme shall be
as approved by the purchaser during detailed engineering stage.
i) The cabinets, panels shall be provided with eye bolts for lifting.
ii) Sheet steel thickness for local panels, system cabinets shall not be less
than 1.6 mm unless otherwise specified.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
falling objects, water etc. The canopy shall not be less than 3 mm thick
steel, and extended beyond the ends of the rack. Bulk heads, especially
designed to provide isolation from process line vibration shall be
provided. Exact fabrication details shall be as finalised during detailed
engineering stage. The junction box for racks also shall conform to IP 55
protection class.
ii) Transmitters and switches, devices, etc. mounted in the field shall be
suitably grouped together and mounted in local instruments enclosures/
racks. These local instrument enclosures and racks shall be furnished
as per the actual requirements finalised during detailed engineering
stage. The exact grouping of instruments in a particular instrument
enclosure/instrument rack shall be as finalised during detailed
engineering stage subject to the purchaser's approval.
iii) The local instrument enclosures shall be constructed of 1.6 mm sheet
plate and shall be of modular construction with one or more modules and
two end assemblies bolted together to form an enclosure. Channel and
frame shall be 3 mm thick. Double inter locking doors shall be provided.
The doors shall be the three-point locking type constructed of not less
than 1.6 mm thick steel. Doors shall have concealed quick removal type
pinned hinges and locking handles. Door locks shall accept the same
key. Gaskets shall be used between all mating sections to achieve
protection class of IP-55.
iv) Vibration dampeners shall be installed for supporting each enclosure.
v) The internal layout shall be such that the impulse piping/ blowdown lines
are accessible from back doors of the enclosure and the transmitters etc.
are accessible from front side for easy maintenance.
vi) Each transmitter enclosure housing instruments requiring purge air for
continuous air purging, shall be provided with common purge air header,
redundant air filter regulators of sufficient capacity, required pressure
gauges, valves, fittings, SS tubings and individual purge meters for
each purge line etc. as required and indicated in Instrument Installation
drawings enclosed herewith.
vii) A 15 mm NB service air header shall be furnished in each enclosure
housing instruments requiring intermittent purging. The header shall be
furnished complete with a pressure regulating valve, pressure gauge,
and quick disconnect connections. A hose for connecting each header
to the draft instrument line four- way valves shall be furnished. The hose
shall be self-storing nylon tubing having a burst pressure of 15 kg/sq.cm.
The size of the hose shall be 1/2" minimum. The service air header shall
originate at a bulkhead penetration or fitting located on one of the
bulkhead plates.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
ii) All output signals of all stack monitoring analyzers shall be hardwired
and connected to FGD PLC as applicable for monitoring, archiving and
report generation for environmental monitoring authorities. The OWS
shall be equipped/loaded with necessary boiler/ stack emission
monitoring system’s calculations and report generation software
packages for generation of report for submission to environmental
monitoring authorities.
iii) Each analyser shall be independent and shall not share power supply
processor etc. with other analyser except compressor for purging air.
Separate compressor shall be provided as a part of CEMS.
v) The gas analyzers shall also follow the latest norms of Central Pollution
Control Board/ SPCB. The measurement shall also conform to EPA,
TUV, MCERTS or equivalents regulations.
vi) Power supply to CEMS shall be from FGD plant UPS only.
vii) Output of CO/ SOx & NOx/ CO2/ Dust monitors/ Stack flow analyser shall
be normalized for Temperature, Pressure, Water vapour etc. This facility
should be available in the respective gas analyzer.
viii) Weather protection against direct sunlight, rains etc. for flow meter, local
display/local indicators shall be provided.
6.8.2 The CEMS shall comprise of following equipment for each unit:
i) SO2/NOx analyser
ii) CO analyser
iii) CO2 analyser
iv) Flue gas flow meter
v) Flue gas temperature measurement
vi) Stack opacity monitor
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
249
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
250
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
6.8.4 Specific requirements for Hot-extractive sampling type SO2/NOx, CO2 &
CO analysers:
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
The sampling system shall consist of in-situ dilution probe, dilution probe
controller, sample conditioning system like air drier and filters etc. and other
accessories meeting the following requirements as a minimum. All system
components and accessories required for completion of this system shall be
furnished although these may not be individually specified herein.
The design of the Dilution Extractive type system shall be satisfying the
following requirements:
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
Zero drift < 1 ppb/ day < 0.5 ppb/ day ≤ 1 ppm/ < 0.1 ppm/day
day
span drift (+/- 1%F.S./ day) (+/- 1%F.S./ (+/- 2%F.S./ (+/- 1%F.S./
day) day) day)
Lower ≤ 1.0 ppb ≤ 0.4 ppb ≤ 1 ppm 0.05ppm
detection
limit.
Response 100 sec. 60 sec. 90 seconds 60 seconds
time up
to 95% of full
scale)
Accuracy/ +/- 1% +/- 1% +/- 1% +/- 1%
Precision.
Linearity (+/- 1% Full (+/- 1% Full (+/- 1.5% +/- 1% of
scale) scale) Full scale) F.S.
Operating 50C - 400C 50C - 400C 50C - 400C 50C - 400C
Temp for
analyser
6.8.6 Specific requirements for in-situ (Path) type SO2/NOx, CO2 & CO
analysers :-
Linearity ± 2% of F.S. ± 1% of ± 1% of
measurement range measurement
range
Repeatability < 0.5% of Span
Response time(up < 5 seconds
to 90%
of full scale)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
254
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
255
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
256
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
6.8.10 Sampling type /Dilution extractive type systems shall be provided with dual
sample probes along with all required accessories such as redundant heavy
duty pumps with continuous rated motors, moisture detection facility, pre-
fabricated heated (for sampling type only) sample lines from probes to analyser
panel, solenoid valves, filters, coolers along with level switch in gas coolers for
auto draining purpose and flow meter etc. as applicable.
i) The bidder shall supply, erect, terminate and test all instrumentation
cables for control and instrumentation equipment/devices/systems
included under bidder's scope.
ii) Any other application where it is felt that instrumentation cables are
required due to system/operating condition requirements, are also to be
provided by the bidder.
iii) Other type of cables like co-axial cables for system bus, cables for
connection of peripherals etc. (under Bidder's scope) are also to be
furnished by the Bidder.
iv) Bidder shall supply all cable erection and laying hardware like cable
trays, supports, flexible conduits, cable glands, lugs, pull boxes etc. on
as required basis for all the systems covered under this specification.
i) All the instrumentation cables i.e. twisted and shielded multipair cables,
compensating cables, pre fabricated cables etc. shall be flame retardant
low smoke (FRLS) type. The Cables shall be provided in non returnable
drums. The drum length shall be 1000m (+/-5%) up to & including 8
pairs and 500 m (+/- 5%) above 8 pairs.
ii) Voltage grade of the instrumentation cables shall be 225V (peak value).
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
iii) All instrumentation cables covered in this specification shall comply with
VDE 0815, VDE 0207, Part 4, Part 5, Part 6, VDE 0816,VDE 0472, SEN
4241475, ANSI MC 96.1, IS-8784, IS-10810 (latest editions) and its
amendments read along with this specification.
iv) The conductor shall be of minimum 0.5 sq.mm size, high conductivity,
multi-stranded copper for all types of instrumentation cables.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
(c) Smoke density rating shall not be more than 60% during smoke
density test as per ASTMD-2843. The results of smoke density
test shall be plotted on a curve indicating light absorption v/s time
as per ASTMD 2843. The average area under the curve (smoke
density rating) shall not be more than 60%.
(d) Complete cable assembly shall pass Swedish Chimney test as per
SEN-4241475 and flammability test as per IEEE-383.
The thickness of outer sheath shall be as per the guidelines given in VDE
0816. Thickness of outer sheath shall not be less than 1.8 mm in any
case. Allowable tolerance of overall diameter of the cables shall be +/-2
mm max. over the declared value in technical data sheets. The variation
in diameter and the ovality at any cross section shall not be more than
0.1 mm.
Table –
A
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
Cross-Talk 60 dB 60 dB 60 dB 60 dB
figure at
0.8 kHz
(min.)
Charact- 320 ohm 340 ohm 320 ohm
eristic
impedan
ce
(max.)
Attenuati 1.2 dB/km 1.2 dB/km 1.2 dB/km
on at 1
kHz
(max.)
xv) Description of various type of cables
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
261
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
262
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
Detector/ JB Shielded,
Isolator/ Twisted,
Interface PVC Cu.
Unit FRLS
cables Type “S”
Refer Note 3
below.
JB Fire alarm Panel Shielded,
Twisted,
PVC Cu.
FRLS
cables Type “S”
Refer Note 3
below.
Notes:
1. 10% spare pair shall be provided for all cables having more than
four pairs.
2. For analog signals, individual pair shielding & overall shielding &
for Binary signals, only overall shielding of instrumentation cables
shall be provided.
3. Type “S” cable shall satisfy requirements of Article 760 NFPA 70.
4. Short term fire proof cables shall be Mineral insulated copper
conductor and copper sheathed type satisfying requirements of
Fire resistance, safety in the industrial application areas
mentioned in the specification and also, shall be approved by UL
standards and certified by LPCB.
i) Fiber Optic cable shall be 4/8/12 core, corrugated steel taped armoured,
fully water blocked with dielectric central member for outdoor/indoor
application so as to prevent any physical damage. The cable shall have
multiple single-mode fibres as required by the communications system
so as to avoid the usage of any repeaters. The core and cladding
diameter shall be 9±1 micrometers and 125±1 micro-meters
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
ii) The cable core shall have suitable characteristics and strengthening for
prevention of damage during pulling viz. Steel central member, Loose
buffer tube design, 4 fibers per buffer tube (minimum), Interstices and
buffer tubes duly filled. The cable shall be suitable for a maximum tensile
force of 2000 N during installation, and once installed, a tensile force of
1000 N minimum. The compressive strength of cable shall be 3000 N
minimum. The operating temperature shall be –20 deg C to 70 deg C.
iii) All testing of the fiber optic cable being supplied shall be as per the
relevant IEC, EIA and other international standards.
iv) Bidder to ensure that minimum hundred (100) percent cores are kept as
spares in all types of optical fibre cables.
ii) All the terminal blocks shall be provided complete with all required
accessories including assembly rail, locking pin and section, end brackets,
partitions, small partitions, test plug bolts and test plug (as specified above
for SWGR connections) transparent covers, support brackets, distance
sleeves, warning label, marking, etc.
iii) The marking on terminal strips shall correspond to the terminal numbering
on wiring diagrams. At least 20% spare unused terminals shall be provided
everywhere including local junction boxes, instrument racks/enclosures,
termination/marshalling cabinets, etc. All terminal blocks shall be numbered
for identification and grouped according to the function. Engraved labels
shall be provided on the terminal blocks.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
iv) The terminal blocks shall be arranged with at least 100 mm clearance
between two sets of terminal blocks and between terminal blocks and
junction box walls.
ii) Wiring to door mounted devices shall be done by 19 strand coper wire
provided with adequate loop lengths of hinge wire so that multiple door
opening shall not cause fatigue breaking of the conductor.
iii) All internal wires shall be provided with tag and identification nos. etched
on tightly fitted ferules at both ends in purchaser's approved format. All
wires directly connected to trip devices shall be distinguished by one
additional red colour ferrule.
iv) All external connections shall be made with one wire per termination
point. Wires shall not be tapped or spliced between terminal points.
vi) All the special tools as may be required for solderless connections shall
be provided by Bidder.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
iii) Cables shall terminate in the enclosure through cable glands. All cable
glands shall be properly gasketed. Fire proof sealing to prevent dust
entry and propagation of fire shall be provided for all floor slots used for
cable entrance.
i) Bidder shall supply and install all cable accessories and fittings like cable
glands, grommets, lugs, termination kits etc. on as required basis.
iv) Cable tray numbering and marking to be provided at every 10m and at
each end of cable way & branch connection.
vi) Buried cable protection to be provided with concrete slabs; route markers
at every 20 meters along the route & at every bend.
vii) At road crossings, cables to pass through buried high density PE pipes
encased in RCC. At least 300 mm clearance shall be provided each
between HT Power & LT Power cables and LT Power & LT
266
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
control/instrumentation cables.
Spacing between cables of same voltage grade shall be in accordance
with the derating criteria adopted for cable sizing.
viii) All cable associated with the unit shall be segregated from cables of other
units. Interplant cables of station auxiliaries and unit critical drives shall be
segregated in such a way that not more than half of the drives are lost in
case of single incident of fire.
ix) All cables laid on trays shall be neatly dressed up & suitably
clamped/tied to the tray. For cables in trefoil formation, trefoil clamps shall
be provided.
xi) Bidder shall supply and install all cable accessories and fittings like Light
Interface Units, Surge suppressors, Opto isolators, Interface Converters,
Fiber Optic Card Cage, Fiber Optic Line Driver, Modem (for Optical Fiber
Cables), cable glands, grommets, lugs, termination kits etc. on as required
basis.
xii) Bidder shall furnish two completely new sets of cable termination kits like
crimping tools, maxi-termi/wire-wrap tools etc. which are required for
maintenance of the system.
iii) Type Screwed at all four corners for door. Door handle shall
be of SS. Self locking with common key. Door gasket
shall be of synthetic rubber.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
6.9.10 Conduits
All rigid conduits, couplings and elbows shall be hot dipped galvanised rigid
mild steel in accordance with IS:9357 Part-I (1980) and Part-II (1981). The
conduit interior and exterior surfaces shall have a continuous zinc coating with
an overcoat of transparent enamel lacaner or zinc chromate. Flexible conduit
shall be heat resistant lead coated steel, water leak, fire and rust proof. The
temperature rating of flexible conduit shall be suitable for actual application.
i) The Contractor shall furnish the type test reports of all type tests as
per relevant standards and codes as well as other specific tests
indicated in this specification. A list of such tests are given for various
equipment in subsequent table and under the item Special
Requirement for Solid State Equipments/ Systems. For the
balance equipment instrument, type tests may be conducted as per
manufactures standard or if required by relevant standard.
iii) For the rest, submission of type test results and certificate shall be
acceptable provided.
c. The test has been carried out as per the latest standards along
with amendments as on the date of Bid opening but not more
than five (5) year back.
iv) In case the approved equipment is different from the one on which
the type test had been conducted earlier or any of the above grounds,
then the tests have to be repeated and the cost of such tests shall be
borne by the Bidder/ sub-vendor within the quoted price and no extra
268
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
i) The minimum type test reports, over and above the requirements of
above clause, which are to be submitted for each of the major C&I
systems Analyzer instruments, various PLCs etc. shall be as indicated
below:
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
Temp IS -3624 No No
interference
test
270
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 6 (Control & Instrumentation Works)
redundant
fans
SWC test Approved No Yes
procedure,
Efficiency/ IEC-146- Yes Yes
PF 2,IEC146
Audible IEC 146-2 No Yes
noise test
Fuse Approved No Yes
clearing procedure
capability
Relative Approved No Yes
harmonic procedure
content
Radio IEC 146-4 No Yes
interference
Over Load Approved No Yes
test on procedure
inverter &
charger.
Restart test IEC 146-2 No Yes
Output Approved No Yes
voltage procedure
tolerance
Output Approved No Yes
voltage procedure
harmonic
content
Insulation IEC 146 No Yes
test
Load tests Approved Yes Yes
procedure
Preliminary IEC 146 No Yes
light load
test
Current IEC 146-2 No Yes
division/
voltage
division
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Section-7 (Civil Works)
SECTION-7
CIVIL WORKS
7.1 GENERAL
7.1.1 The specification for civil works covers all the civil works required for
installation/retrofitting of Limestone based FGD Plants inside the premises of
existing Thermal Power Plants. The specifications are intended for the general
description of the work, materials quality and workmanship. The specifications
are not, however, intended to cover the minute details.
Wherever references to Indian Standard Codes are made, they shall refer to the
latest edition/ version of the same as exist one month before the due date of
submission of tenders.
The work shall also involve the dismantling of existing R.C.C. foundation,
pedestals, structures etc. without blasting/ disturbing the nearby foundations/
structures at the interface of existing power plant and proposed FGD plant or at
any other place for accommodating the facilities of FGD plant. Dismantling works
shall be done as per the strict instruction of the Purchaser.
The bidders are advised to visit the project site to acquaint themselves of the
actual site conditions before submission of the bids.
7.1.3 Scheme
The proposed scheme and technical details of FGD system are described
elsewhere in Technical specification.
The layout and levels of all structures etc. shall be made by the Contractor at his
own cost from the general grid of the plot and bench marks given by the
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The Bidder shall submit along with his offer drawings, Bar Chart, Schedule, list
of construction equipment’s and manpower to be deployed and a write-up to
indicate broadly how he intends to execute the work. These shall from part of
this tender.
7.2.1.2 Live load: The following live loads shall be adopted in addition to equipment
and machinery loads as per IS: 875 (latest revision) including up-to-date
amendments:
f) Platforms, walkways
grating floors = 500 kg/sqm
Any other load required for servicing, maintenance and erection shall be taken
in addition to above loads. Further, if erection load on any floor or part thereof is
more than the live load specified above, that floor including beams shall be
designed for the erection load.
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7.2.1.3 Wind load: Wind loads on structures shall be calculated as per provisions of
IS-875 (Part-3) including up-to-date amendments.
7.2.1.4 Seismic load: Seismic load shall be calculated for analysis & design as
applicable by seismic coefficient/response spectrum method as per IS: 1893
(latest revision) including up-to-date amendments. The Importance factor for all
structures shall be taken as 1.50.
7.2.1.5 Dust load: All buildings and structures shall be designed for a dust load of 50
kg/sqm.
7.2.1.6 Thrust load: All pipes and its foundation at bends shall be designed for thrust
load as per latest edition of IS: 5330.
7.2.1.7 Impact load: The minimum impact factor to be used in design shall be as
follows:
(c) For pulley block 10% for manual and 25% for
electrical
7.2.1.8 Thermal load
The surge effect of cranes in the lateral & longitudinal horizontal shall be
considered as per manufacturer’s recommendations and relevant IS codes.
The underground structures shall be designed for lateral thrust due to earth
pressure, sub-soil water pressure (if any). In addition, a minimum surcharge load
of 2.0 tonne per sq.m. shall also be considered. The structures/foundations shall
be checked for buoyancy effect due to sub-soil water table.
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7.2.1.11 Increase in allowable stresses: While designing structures for wind and
seismic loads, the permissible stresses in materials and safe bearing capacity
of soils may be increased as allowed by relevant I.S. Codes.
7.2.2 Safe bearing capacity of soil: Before submitting the tender, the tenderer
should familiarize himself with the site conditions and shall satisfy himself about
nature of soil, bearing capacity etc. and furnish all inclusive rates of various items
of work below ground level. The report of soil investigation of existing power
plant is available with the Purchaser, which can be seen by the bidders
with prior appointment. However, the contractor shall carry out soil
investigation after award of work for determining the safe bearing capacity of the
soil including sub-soil water level and for deciding the type of foundations to be
provided for various structures of FGD Plant.
7.2.3 The owner shall not, under any circumstances, pay any extra charge after the
acceptance of the contract, in case the contractor is found to have misjudged
the soil conditions including sub-soil water level at the site of work at a latter
date.
7.2.4 DESIGN CRITERIA
7.2.4.1 The design of R.C.C. structures will be carried out as per code of practice for
plain and reinforced concrete for General Building Construction IS:456 (latest
edition). The design of liquid retaining R.C.C. structures shall be carried out as
per latest edition of IS: 3370 (Part I to IV).
7.2.4.2 The steel structures shall be designed and fabricated as per latest edition of IS:
800 entitled ‘Code of Practice for use of Structural Steel in General Building
Construction’ and other relevant IS Standards.
7.2.4.3 The building shall conform to local by laws, rules and regulations for industrial
buildings and also to IS: 1256 (latest revision).
7.2.4.4 The machine foundations shall be designed in accordance with latest edition of
IS: 2974. The vibration isolation system may be provided for Booster Fans,
limestone crushers, Ball Mills or any other heavy vibratory equipment as
specified elsewhere in the specifications.
7.2.4.5 The permissible settlement for foundations of FGD plant shall be as per relevant
IS codes and differential settlement shall be as per IS: 8009 unless required
otherwise by the manufacturer of any equipment.
7.2.4.6 All Control Room Buildings shall be air-conditioned and shall have provision for
false ceiling and anodized aluminium doors & windows. All windows in air
conditioned buildings shall be double glassed
7.2.5 DESIGN CALCULATIONS AND DRAWINGS: All drawings and design
calculations (six sets) for civil & structural works shall be submitted by the
contractor for the approval of owner/Consultants. No construction shall
commence prior to approval of the relevant design and construction drawings.
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7.3.1 GENERAL
This shall include all works involved in excavation for all leads and lifts, dressing
of soil, shoring, filling around foundations and trenches, carting of sand or good
quality earth if required for filling, disposal of residual earth at a place as directed
by the Purchaser. The contractor must satisfy himself of the character and
volume of all works under this item and expected surface and/or sub-soil water
to be encountered.
7.3.2 EXCAVATION
7.3.2.1 The contractor shall control the grading in the vicinity of all excavations so that
the surface of the ground will be properly sloped or diked to prevent surface
water from running into the excavated areas during construction.
7.3.2.2 Sides and bottoms of excavation shall be cut sharp and true to the slopes
indicated in the drawing. Under-cutting shall not be permitted. Earth side of
excavation shall not be used in lieu of formwork for placement of concrete unless
authorised in special cases, by the Purchaser where limitation of space for larger
excavation necessitates such a decision.
7.3.2.3 When machines are used for excavation, the last 300mm before reaching the
required level shall be excavated by hand or by such equipment that will leave
the soil at the required final level, in its natural condition. Similarly, excavation
by hand may be required close to existing installation.
7.3.2.4 Suitability for bearing of the bottoms of excavations shall be determined by the
Purchaser.
7.3.2.5 The bottoms of excavations shall be trimmed to the required levels and when
carried below such levels due to contractor's fault, the excess depth shall be
filled up to the required level at the Contractor's cost with cement concrete not
leaner than M-10 grade or richer as directed by the Purchaser in each individual
case.
7.3.2.6 Excavated material shall be placed beyond 1.5m from the edge of the pit or half
the depth of the pit whichever is more or farther away if directed by the
Purchaser.
7.3.2.7 All excavations for installation of underground facilities such as piping, power
lines, ducts, drain lines, earthing mat etc. shall be open cuts.
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7.3.2.8 Excavation for foundation where specified shall be carried out at least 100mm
below the bottom of structural concrete and then brought to the required level
by placing lean concrete of M-10 (1: 3: 6) with aggregates of 40mm maximum
nominal size.
7.3.2.9 For the purpose of excavation of earthwork, the term soil shall apply to all kinds
of soil containing any percentage of Kanker, moorum or/and shingle etc. Any
buried structures or foundations or reinforced/un-reinforced cement concrete
found at site during excavation shall also be removed/dismantled, if required,
without any extra cost to the purchaser.
7.3.3 DISPOSAL OF SURPLUS EARTH
The contractor shall arrange to transport the surplus excavated soil remaining
after backfilling to the disposal place inside the project area, as directed by the
Purchaser.
7.3.4.2 The Contractor shall de-water and maintain the water table below the bottom
of the excavated level during excavation, concreting, water proofing treatment
and backfilling and shall continue the arrangements till the completion of all
works up to 1.0m above the water table is achieved.
7.3.4.4 All costs for the ground water control for keeping the construction pits dry shall
be included in the relevant excavation item except otherwise indicated.
7.3.5 BACKFILL
7.3.5.1 The Contractor shall furnish all labour, equipment and materials required for
complete performance of work in accordance with the drawings and as
described herein.
7.3.5.2 After completion of foundation footings and wall and other constructions below
the elevation of the final grades and prior to backfilling, all forms, temporary
shoring, timber etc. shall be removed and the excavation cleaned of all trash,
debris and perishable materials.
7.3.5.3 Backfilling shall be done with inorganic materials obtained from the excavation
or borrow pits, if suitable, and subject to the approval of the Purchaser.
7.3.5.4 Backfill shall be placed in horizontal layers not exceeding 20cm in thickness.
Each layer shall be compacted with proper moisture content with such
equipment as may be required to obtain a density requirement as per standard
proctor test conforming to IS 2720.
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7.3.5.6 Backfill adjacent to pipes shall be hand placed free from stones, concrete etc.
compacted uniformly on both sides of the pipe and where practicable to a depth
of 300mm over the top of pipes.
7.3.5.7 On completion of structures, the earth surrounding them shall be accurately
furnished to the specified line and grade. Finished surface shall be free of
irregularities and separations and shall be within 50mm of the specified level.
7.3.6 EXCAVATION IN TRENCHES FOR PIPES, CABLES
Excavation not exceeding 1.50 m or 10m2 in plan to any depth in trenches shall
be described as trenches for pipes, cables etc. Returning, filling and ramming
(after pipes and cables are laid) and removal of surplus soil shall from part of
this work.
For depth up to 1.0m, the width shall be arrived by adding 25cm to the external
diameter of pipe (not socket). When pipe is laid on concrete bed/ cushioning
layer, the width shall be pipe diameter plus 25 cm or the widths of concrete bed/
cushioning layer whichever is more.
For depths exceeding 1.0m, an additional width of 5 cm/m depth for each side
of trench shall be taken i.e. diameter of pipe + 25cm +(2 x 5) cm
When more than one pipe, cable, conduit are laid, the diameter taken shall be
the horizontal distance from outside to outside of outermost pipes, cable etc.
The bedding surface shall provide firm foundation of uniform density throughout
the length of the culvert, shall conform to the specified levels and grade, and
shall be of one of the following two types as specified on the drawings:
Under first class bedding, the pipe shall be evenly bedded on a continuous layer
of well compacted approved granular material, shaped concentrically to fit the
lower part of the pipe exterior for at least ten per cent of its overall height or as
otherwise shown on the drawings. The bedding material shall be well-graded
sand or another granular material passing 4.75mm sieve. The thickness of the
bedding layer shall be as shown on the drawings and in no case shall it be less
than 75mm.
When indicated on the drawings or directed by the Purchaser, the pipe shall be
bedded in a cradle constructed of concrete having a mix not leaner M20
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7.3.6.3 Filling
7.3.6.3.1 Normally excavated earth shall be used for filling. In case earth contains
deleterious salts it shall not be used. Where excavated material is rock, the
boulders shall be broken into pieces not bigger than 15 cm & mixed with fine
materials of decomposed rock, murrum or earth as available to fill up voids.
7.3.6.3.2 Filling the trenches for pipes shall start after the joints of pipes etc. are tested
& passed. Where the trenches are excavated in soil, the filling shall be done
with earth on the sides & top of pipes in layers not exceeding 20 cm watered &
rammed and consolidated.
7.3.6.4.1 All trenches exceeding 2.0m in depth shall be shored & timbered as determined
by the Purchaser. The above requirements do not apply in cases where the
sides of the trenches are sloped to within 1.5m of bottom.
7.3.6.4.2 Approved quality SAL wood shall be used for shoring and timbering a trench.
7.3.7 MISCELLANEOUS
7.3.7.1 The Contractor shall take adequate safety measure around the excavated pit
by providing fencing and sufficient illumination with red lights during night to
avoid accident in the excavated areas.
7.3.7.2 If any materials like steel pieces, parts of any equipment etc. are found during
excavation, the matter shall be brought to the notice of the Purchaser
immediately and the same shall be deposited in the project’s store by the
Contractor at his own cost. Any finds of archaeological interest such as relies
of antiquity, coins, fossils or other articles of value shall be delivered.
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7.4.2 MATERIALS
7.4.2.1 Cement
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7.4.3 Water
Water shall be clean, fresh and free from organic or other deleterious matters in
solution or in suspension in such amounts that may impair the strength or
durability of the concrete. Potable water is generally satisfactory. IS 3025 and
IS 3550 (latest edition) may be followed for testing, if required. The permissible
limit of solids shall be within limits corresponding to table-I of IS 456 (latest
edition).
7.4.5.2 General storage shall be carried out by the Contractor in a manner affording
convenient access for identification and inspection at all items. The storage
facilities shall be subject to approval of the Purchaser.
7.4.6 Grade of Concrete
7.4.6.1 General
Concrete shall be design mix and in grades designated as M-15 and above as
specified in IS 456 (latest edition). In case of liquid retaining structures, IS: 3370
(latest edition) shall be followed. Lean concrete shall be M-10 mix with
aggregate of nominal size 40mm maximum or as indicated in drawings. Nominal
mix is recommended only when accurate control is impracticable and not
necessary.
7.4.6.2.1 If nominal mix concrete is allowed by the Purchaser, it shall be used only for
the concrete of grade lower than M-20.
7.4.6.2.2 Concrete mix proportions and minimum cement content for design mix concrete
shall be as per IS: 456(latest edition).
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7.4.6.2.3 If nominal mix concrete made in accordance with the proportions given in
Table-9 of IS:456-2000 for a particular grade does not yield the specified
strength and fails to satisfy the requirements of "Acceptance criteria for concrete"
as specified under clause 16 of IS: 456-2000, the cement content shall be
increased as directed by the Purchaser to obtain a specified strength at no extra
cost to the Purchaser.
7.4.6.3.2 The minimum grade of concrete for plain concrete shall be M-15. The minimum
grade of reinforced cement concrete shall be M-25 for all substructure and
superstructure except that for equipment foundation or water retaining
structures where minimum grade of concrete is taken as M30.
7.4.6.3.3 Maximum Cement Content: Cement content not including fly ash and ground
granulated blast furnace slag in excess of 450 kg per cubic metre should not be used
unless special considerations have been given in design to increased risk of cracking
due to drying shrinkage.
7.4.6.3.4 The mix proportions for all grades of concrete shall be designed as per IS:
456(latest edition).
7.4.7.1 General
Concrete shall not be placed in any unit of the work until after the forms, bracing,
reinforcing steel and other preparations for casting have been approved by the
Purchaser and approval given to proceed with the casting.
7.4.7.2 Mixing
7.4.7.2.1 Concrete shall be mixed till there is a uniform distribution of materials and shall
be discharged completely before the mixer is recharged. Mixing shall be done
in a mechanical mixer. The mixer shall be rotated at a speed recommended
by the manufacturer and mixing shall be continued for at least two minutes
after all materials are in the drum. For batches larger than 0.75 cum. mixing
time shall be increased by 15 seconds for each additional 0.75 cum. or fraction
thereof. All concrete shall be discharged within 3minutes after the introduction
of mixing water to the cement and aggregates or the introduction of cement to
the aggregate unless a different time is specified by the Purchaser.
7.4.7.2.2 All hardened concrete and foreign materials shall be removed from the inner
surfaces of mixing and conveying equipment. All conveyances, buggies and
barrows shall be thoroughly cleaned at frequent intervals during the placing of
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concrete. Concrete shall be rapidly handled from the mixers to the place of
final deposit and shall not be delivered by spout or trough nor dumped into
carriers with a free fall from the mixer of more than 1.5 meter.
7.4.7.2.3 Each time the work stops, the mixer shall be thoroughly cleaned and when the
next mixing commences, the first batch shall have 10% additional cement at
no extra cost to the owner to allow for loss in the drum.
7.4.7.2.4 The workability of the concrete shall be checked at frequent intervals by slump
test, where facilities exist and if required by the Purchaser, alternatively the
compacting factor test in accordance with IS: 1199 be carried out.
7.4.7.3.2 Concrete shall not ordinarily be placed under water. In unavoidable cases,
such concreting shall be done only with, the specific approval of procedure and
application by the Purchaser. Additional cement shall be to the extent of 10%
and relevant clauses of IS: 456 (latest edition) adhered to.
7.4.7.3.3 To secure maximum density and eliminate formation of all pockets, the
concrete shall be thoroughly vibrated by mechanical vibrator and worked
around all reinforcement, embedded facilities and into corners of forms during
and immediately after placing.
7.4.7.3.4 Retamping of concrete or mortar which has partially hardened shall not be
permitted.
7.3.7.3.5 Normally no concreting shall be done at night, however in case concreting
during night becomes necessary proper lighting arrangement shall be made
beforehand for concreting to continue at night.
7.4.8 Construction Joints
7.4.8.1 Construction joints must be approved before concrete is poured and shall comply
with IS 11817 (latest edition).
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the continuity of reinforcement. This particle board shall be removed after the
concrete has set-in sufficiently to retain its verticality and shape, before
concreting is resumed in the adjacent portion.
7.4.8.6 Construction joint between floor and vertical wall of water tank shall be provided
with PVC water stops. Concurrence and approval of the Purchaser will have to
be obtained before providing such joints.
7.4.9 Inserts
The embedded portion of all anchors, anchor bolts, inserts, pipe, conduit,
sleeves, floor angles, frames, nosing bolts etc. shall be black without any coating
or painting. All the inserts to be cast into the concrete shall be placed in correct
position before pouring. Block-outs and openings shall be kept wherever
required.
Except where a special finish is called for, all exposed concrete shall be finished
as follows:
7.4.10.1 All fins and other projections shall be neatly chipped, rubbed down and made
smooth; form oil shall be entirely removed by stiff fiber brushes. The use of
acid shall not be permitted. All exposed corners shall be slightly rounded or
chamfered. Air holes, cavities and similar imperfections shall be first saturated
with water and filled with a mortar mixture of the same composition as that used
in the concrete. After initial set of mortar, the surface shall be rubbed down
with burlap. A stucco coat shall be allowed to be applied to the surfaces. The
inside surfaces shall be ground smooth with carborundum stone.
7.4.10.2 Except where a separate finish is to be applied, or where a trowel finish is called
for horizontal concrete surfaces shall be floated.
7.4.10.3 Where a trowel finish is called for the surface shall be floated and steel troweled
after achieving initial set to prevent excess fine materials from working to the
surface. The finish shall be brought to a smooth dense surface free from
defects and blemishes. No dry cement nor mixture of dry cement and sand
shall be done after the concrete is so hard that no mortar accumulates on the
trowel and a ringing sound is produced as the trowel is drawn over the surface.
7.4.11 Curing
7.4.11.1 Unless otherwise specified all concrete shall be cured by keeping all exposed
surfaces, edges and corners continuously moist for at least seven days for
ordinary Portland cement after being placed, by spraying, ponding or covering
with waterproof paper or moisture retaining fabric. In case where mineral
admixtures or blended cements are used, minimum period of curing shall be
increased to 10 days.
7.4.11.2 For the concrete containing, Portland pozzolana cement, blended cement,
period of curing shall be extended to 14 days.
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7.4.12.3 All forms shall be thoroughly cleaned and sufficiently tight to prevent the loss
of liquid from the concrete.
7.4.12.4 Form lumber may be reused, provided that it is true, unwrapped, thoroughly
clean and without broken or damaged edges and equal in use in every respect
to a new lumber. All reform lumber shall have the contact surfaces recoiled or
re-coated with an approved composition prior to usage.
7.4.12.5 Contractor shall keep an accurate record of the date on which the concrete is
cast for each part of the work and the date upon which the formwork is
removed.
7.4.12.6 In normal circumstances and where ordinary Portland cement is used and
adequate curing is done, forms may generally be removed after the expiry of
the followings:
For cement other than ordinary portland cement, the stripping time required as
per 7.4.12.6 shall be suitably modified as per Purchaser instruction.
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The Tolerances on the shapes, lines and diversion are given below:
7.4.14.2 Cement
i) All deliveries of cement shall be accompanied by certified mill test report
and shall include all the physical and chemical properties as required by
relevant IS codes.
ii) The manufacturer’s test certificate will normally be accepted as proof of
compliance with the specifications, but the Purchaser may order further
tests as specified in appropriate Indian standards.
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7.4.14.4 Water
Sampling and testing of water being used for concrete work as per IS: 3550 will
be carried out at regular intervals and wherever directed by the Purchaser. The
permissible limit for solids shall be as per table-I of IS-456 (latest edition). Water
used for mixing is also suitable for curing concrete however, they should not
produce any objectionable stain. The pH value of water shall not be less than 6.
7.4.14.5 Admixtures
Tests for establishing the various properties of any admixtures which may be
required to be added shall be carried out by the contractor free of charge to the
owner. Admixture shall comply with IS-9103. Admixtures should not impair
durability of concrete nor combine with constituent from harmful compounds nor
increase the risk of corrosion. The workability, compressive strength and slump,
loss of concrete with & without the use admixtures shall be established during
trial mix.
7.4.14.6 Concrete
i) The sampling of concrete, making the test specimen and testing procedure
etc. shall be in accordance with IS: 1119 and IS: 516. The size of the
specimen shall be 15cm cube. Normally only compression tests shall be
performed but under special circumstances the Purchaser may require
other tests to be performed in accordance with IS: 516.
ii) Procedure laid down otherwise in IS: 456 shall be followed for sampling and
strength test of concrete.
iii) The acceptance criteria for the compressive strength shall be as per clause
16 of IS :456 -2000.
iv) Concrete of each grade shall be assessed separately.
v) Concrete shall be assessed daily for compliance.
vi) Concrete is liable to be rejected if it is porous or honey combed its placing
has been interrupted without providing a proper construction joint; the
reinforcement has been displaced beyond the tolerances specified or
construction tolerances have not been met. However, the hardened
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7.5.1 Reinforcement
7.5.1.1 Reinforcing steel shall be clean and free from loose mill scales, dust, loose rust
and coats of paints, oil, grease or other coatings, which may impair or reduce
bond. It shall conform to the following:
(i) Mild steel & medium tensile steel bars shall conform to Grade-I of IS: 432
Part-1 (latest).
(ii) High strength steel bars shall conform to IS 1786 (latest) of grade Fe 415,
Fe- 500 or Fe 500D.
7.5.1.2 All steel reinforcements, including and above 6mm diameter shall necessarily
be of tested quality. The untested steel reinforcement shall not be allowed to
be used.
7.5.1.5 Contractor shall fabricate and place reinforcement to shapes and dimensions,
as per IS: 2502 "Code of Practice for Bending and Fixing Bars for concrete
Reinforcement" (latest) and as indicated in approved drawings of the
contractor. The reinforcement shall be either plain corresponding to grade Fe–
250 for M.S. and Fe– 415, Fe500/Fe500D for HYSD bars or deformed steel
bars conforming to relevant I.S. specifications. However, the minimum
elongation for Fe– 415, Fe500/Fe500D shall be as per IS 1786.
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7.5.1.6 The contractor shall prepare bar bending schedule on the basis of the approved
drawings marked released for construction and submit the same for approval
to the Purchaser. No work shall be commenced without the approval of the
Schedule.
7.5.1.7 Any adjustments in reinforcement to suit field conditions and construction joints
other than shown on approved drawings shall be subject to approval of the
Purchaser.
7.5.1.8 The contractor shall adhere strictly to requirements for concrete cover over
steel reinforcement, protection of bars for bonding with future extensions,
columns, ties, splices, laps, spacer bars, temperature reinforcement, mesh
reinforcement and other items in connection with proper placing.
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(b) Coating materials shall be heat cured epoxy resin powders applied by
electrostatic spray process. The minimum thickness of coating shall be
250 micrometer.
(c) Reinforcement required to the bent shall be bent cold and in such a manner
and using plastic or rubber coated formers that there is no direct steel/rebar
contact and that neither bar nor coating is in any way damaged, all in
accordance with the recommendations of the coating factory and to the
approval of Purchaser. After cutting and bending, each bar shall be
thoroughly inspected and any damage repaired. As a precaution, the
external surfaces of all bends shall receive two coats of liquid repair
material, as shall the last 100 mm of each end of each bar. All repairs and
precautionary coating shall be carried out by liquid repair epoxy material as
per manufacturers specifications.
7.5.1.16 Rejection: The Purchaser at his discretion may order random testing of
reinforcement steel and in an event of any failed test reject an entire lot
notwithstanding the manufacturers or coating applicators certificates.
7.5.2.1 For erection of steel embedded parts, the Contractors shall provide necessary
temporary bracing or supports to ensure proper installation of the materials. All
materials shall be erected in the true location as shown in the drawing, plumb
and level. The exposed surface of embedded steel parts like threads etc. shall
be protected for rusting and tempering.
7.5.2.2 The contractor shall provide openings, grooves, etc. in concrete work as required
for erection of equipment and structures.
7.5.2.3 The contractor shall erect all embedded parts in accordance with the
construction drawings and specifications including setting materials in concrete
or grouting pieces in place, furnishing all labour, scaffolding, tools and services
necessary for incidental to its transporting, unloading, storing, handling and
erection.
7.5.2.4 Exposed surface of embedded materials are to be painted with one coat of
approved anti-corrosive paint and/or bituminous paint without any extra cost to
the Purchaser.
7.6.1.1 Masonry products such as face bricks, common bricks and tiles shall be products
of producers or suppliers approved by the Purchaser.
7.6.1.2 All materials shall be delivered to the site, stored and handled so as to prevent
inclusion of foreign substances, damage by breakage, exposure to the weather
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and contact with the soil. Cementitious materials shall be delivered in unbroken
containers or packages and stored in weatherproof enclosures.
7.6.3 Materials
7.6.3.1 Cement shall be ordinary portland cement of 43 grade or 53 grade conforming to
IS 8112 and IS 12269 (latest edition) respectively or Portland Pozzolana cement
conforming to IS 1409 (latest).
7.6.3.2 Water for mortar shall be clean and potable and free of salts, iron and injurious
amounts of organic matter.
7.6.3.3 Sand having fineness modulus not less than 2.25 shall conform to the
requirements of IS: 650 (latest edition) The grading of sand for use in masonry
mortar shall be as per IS: 2116 and IS : 383 (latest edition).
7.6.3.4 Common bricks and face bricks shall conform to the requirements of IS: 1077
(latest edition) and shall be of uniform colour, strength and size. Bricks shall not
absorb more than 20% of their own dry weight when soaked in water.
7.6.3.5 Crushing strength of class designation 10 bricks and brick tiles shall not be less
than 100 kg/sq.cm. and of class designation 7.50 bricks not less than 75
kg/sq.cm.
7.6.3.6 Fly ash bricks shall be used to increase the fly ash utilization in line with
requirement of MoEF&CC notification in this regard. Fly Ash bricks requirements
shall comply to IS: 12894 – 2002. The minimum average wet compressive
strength of fly ash bricks shall not be less than 7.5 N/mm2 and water absorption
ratio shall not be more than 20% by weight after immersion in cold water for 24
hours.
7.6.3.7 Wall ties shall be 6mm mild steel "U" or "Z" shaped 50mm less in depth than the
width of the wall into which they are built, spaced 400mm centers vertically or
provided at every fifth course.
7.6.3.8 Reinforcement for masonry walls wherever required shall be of mild steel 6mm
plain rods, welded/tied to the wall ties at every fifth course of brick work.
7.6.3.9 Samples of all materials shall be submitted for the approval of the Purchaser.
7.6.3.10 Mortar of specified proportions as shown in the drawings shall be mixed by
volume with just enough water added to produce a workable mixture. Only
freshly prepared mortar shall be used. Mortar shall conform the requirements
of IS: 1925 (latest edition).
7.6.4 Bonds and Coursing
7.6.4.1 All masonry walls shall be laid with horizontal courses level and true in English
bond. All masonry units shall be laid up in full beds of mortar with all units butted
solidly against adjacent units with mortar in between.
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7.6.4.2 All masonry units having appreciable water absorption potential shall be soaked
as per relevant IS code.
7.6.4.3 Vertical surfaces of all masonry walls and partitions shall be plumb and true to
line on uneven surface with maximum total variation of 25mm in any plane or
12.5 mm in 5 meters.
7.6.4.4 Where two walls meet or intersect, the masonry course shall be carried up
together, bonding at least fifty percent of the units at the intersection.
7.6.4.5 Horizontal surfaces of masonry not being worked on shall be protected from the
natural elements by the use of non-staining waterproof coverings, properly
secured in place.
7.6.4.6 Brick tiles where shown in drawings shall be laid with staggered vertical joints
and shall be bonded to the brick walls.
7.6.4.7 Masonry in contact with structural steel including beams and columns, shall be
anchored to the steel works as indicated in the drawings.
7.6.5.2 Door frames shall be set plumb and accurately aligned and checked for proper
position
7.6.5.3 Anchors for door frames, copings, bonding walls to concrete and structural steel
and other anchors shall be securely and accurately located and installed.
7.6.6.2 Joints in exterior walls to be left exposed shall be neatly tooled with a weathered
joint.
7.6.6.3 Where masonry shuts penetrating built-in-terms such as doors frames etc. the
joints shall be 6mm wide and raked to a depth of 20mm for subsequent
caulking.
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7.6.7 Cleaning
7.6.7.1 All exposed brickwork shall be scrubbed down with clean water and rinsed
thoroughly.
7.6.7.2 All work stained or discoloured during the process of cleaning shall be replaced
by the Contractor at his own expenses.
7.6.7.3 Green work shall be protected from the effects of sun, rain etc. by suitable
covering. All the masonry work shall be kept constantly moist on the faces for a
period of seven days.
7.6.7.4 The contractor shall carry out all scaffolding and planking necessary for efficient
execution of work at all levels.
7.6.7.5 At the end of construction, the contractor shall ensure proper plugging of all
openings made for supporting the scaffolding.
7.7.1.1 This shall consist of cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 stone
aggregate of 12.5mm nominal size) equivalent to grade M-15 of 50mm
thickness.
7.7.1.2 The surface of the brick work shall be levelled and prepared before laying the
cement concrete. Edges of DPC shall be straight and even. The side shuttering
shall consist of steel forms and shall be strongly and properly fixed so that it does
not get disturbed during compaction and mortar does not leak through. The
concrete mix shall be of workable consistency and dense. When the side
shutterings are removed, the surface should come smooth without any honey
combing.
7.7.2 Curing
The DPC shall be cured for at least 7 days after which it shall be allowed to dry.
Cement concrete shall be allowed to dry for 24 hours after curing and apply a
coat of residual petroleum bitumen of grade VG-10 having penetration 80/100 of
approved qualities and hot bitumen at the rate of 1.7 kg/sq. meter shall be
applied over the dried surface of cement concrete properly cleaned with brushes
and finally with a cloth soaked in Kerosene oil. The bitumen shall be applied
uniformly so that no blank spaces are left anywhere.
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7.8.1.2 Materials
7.8.1.2.1 Cement shall be ordinary portland cement of 33 grade or 43 grade or 53 grade
conforming to IS: 269, IS:8112 & IS:12269 (latest edition) respectively or
Portland Pozzolana cement conforming to IS:1489 (latest edition).
7.8.1.2.2 Water shall be clean, potable and free from salt, acid and injurious amounts of
organic matter.
7.8.1.2.3 Sand shall be clean, fine, sharp siliceous particles free from loam, clay, salts
and organic matter and shall conform to the requirement of IS: 1542 (Latest
edition) and shall be within limits of grading zone IV or zone V.
7.8.1.3 Mortar
Specified mortar shall be used.
7.8.2 Pointing
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7.8.2.1 General
Pointing shall be of the type specified such as ‘flush’, ‘ruled’, ‘cut’, or ‘weather
struck’ and ‘raised’ or ‘cut’ etc.
7.8.2.2.2 The mortar shall be pressed into the raked out joint with a pointing trowel either
flush, sunk or raised according to the type of pointing required. The mortar
shall not spread over the corner, edges, surfaces of the masonry. The pointing
shall then be finished with the proper tool as required for the particular kind of
pointing specified. The superfluous mortar shall then be cut off from the edges
of the lines and the surface of the masonry shall also be cleaned off all mortar.
The finish shall be such that the pointing is of exact size and shape and edges
shall be straight, neat and clean.
7.8.2.3 Curing
The pointing shall be kept wet for 7 days. During this period, it shall be suitably
protected from all damages. The pointing lines shall be truly horizontal and
vertical except where the joints are slanting as in Random Rubbles Masonry.
Lines of joints from different directions shall meet neatly at the junctions instead
of crossing beyond.
7.9.1.1 The concrete floors in the ground floor having earthen sub-grade but excluding
toilet rooms (Flooring of toilet rooms shall be with Vitrified Ceramic Anti-skid
tiles of approved size and make) shall comprise the following:
(i) 100mm thick sand filling. In case of weak soils, 200 mm compacted
stone soling shall be provided.
(ii) 100mm thick cement concrete 1:3:6 (1 cement: 3 coarse sand and 6
graded stone aggregate 10mm & below).
(iii) 38mm thick cement concrete 1:2:4 (1 cement: 2 coarse sand: & 4 graded
stone aggregate 10mm and below).
7.9.1.2 The concrete floors in the intermediate floors of the building except toilet rooms
shall consist of:
i) 38mm thick C.C. 1:2:4 (1 cement: 2 coarse sand: 4 granite stone aggregate
10mm nominal gauge) with 20mm normal size.
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ii) 12mm thick surface hardening treatment, as per specification clause no.
7.9.2
7.9.1.4 Materials
All materials such as cement, fine & coarse aggregates and water shall be as
per standard already stipulated.
7.9.1.6 Installation/laying
7.9.1.6.1 For R.C.C. slabs which are to receive a separate topping the surface treatment
shall be as follows. When the structural slab has partially hardened so that it
will not retain the impression of a broom it shall be brushed with steel bristle
broom removing all laittance and scum. The brooming shall expose some of
the aggregates and score the material to provide a mechanical bond for the
topping material.
7.9.1.6.2 The mixed concrete of proper consistency shall be laid on cement concrete
sub-grade after cleaning the sub-grade of all dirt and loose material & applying
a neat cement slurry of mix 1:1 (1 cement and 1 coarse sand). The concrete
floor shall be laid in panels of size 1m x1m. Alternative panels shall be laid on
one day followed by the other group of alternate panels the next day. The
edges of the panels shall be supported by 3mm thick glass strips.
7.9.1.6.3 The concrete shall be laid gently in the panels and tamped with wooden
mallets till a cream of mortar covers the structure.
7.9.1.6.4 The junction of floor and walls, floors and skirting shall be rounded off as
directed without any extra payment. The dado shall be of 21mm thick cement
mortar 1:3 (1 cement: 3 coarse sand) a floating coat of neat cement up to a
2.10 high. The finished surface shall be cured as per IS specifications.
7.9.2 Floor Hardening Treatment
7.9.2.1 Materials
All materials such as cement, fine and coarse aggregates and water shall be as
per standards already stipulated. Metallic hardener of approved quality only
shall be used.
7.9.2.2 Application
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Curing shall commence only when the top layer has hardened minimum of ten
days & should continue for minimum of ten days.
This covers the requirements to complete the acid/alkali resistant floor laid over
a uniform sub-grade of concrete 1:2:4 either of PCC or RCC to make the
thickness of acid/alkali floor 100mm. Floor shall be provided with three coats of
bituminous acid/chemical resisting paint. Over this, shall be provided 12mm
thick chemical resisting bitumastic laid in 6mm layers. Floor and curb shall be
covered by acid /alkali resisting bricks/tiles of 75mm/40 mm thickness. The
joints, 6mm wide, which shall be raked for a depth of 20mm, shall be pointed
with acid/alkali resisting cement.
7.9.3.2 Materials
7.9.3.2.1 Bituminous acid resisting paint: The material shall be such a composition
that it will meet the requirement of IS: 157 (latest edition). Material shall be
tested as per standards prescribed in IS: 157. This is generally of heavy grade
bituminous corrosion (acid/alkali) resisting paint. It shall have smooth and
uniform consistency. Its drying time shall not be more than 8 hours. Its finish
shall be smooth, glassy and elastic.
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(b) Tiles:- Vitreous Ceramic tiles shall be made of materials like clay, felspar
quartz, tale and vitrified at high temperature in ceramic kilns and kept
unglazed so as to prevent from slipperiness when laid on floor. Tiles shall
conform to IS: 4457(latest edition).
7.9.3.2.4 Acid resistant mortar: - This shall be of silicate type mortar and resistant to
most acids except hydrofluoric and phosphoric acid. This is an intimate
mixture of chemically inert solid filler, a setting agent contained in filler and a
liquid silicate binder. When filler and binder are mixed at ordinary temperature,
a trowelable mortar is formed which hardens by chemical reaction between
the joint.
Mortar shall conform to IS: 4832 (Part-I)(latest edition). Its flexural strength (7
days) shall not be less than 35 kg/sq.cm. Its compression strength (7 days)
shall not be less than 100 kg/sq.cm.
7.9.3.2.5 Acid/alkali resistant cement:- It shall be supplied in powder and syrup form
to meet the requirements of acid and alkali resistance. It shall be resistant to
sulfuric acid, hydrochloric acid, sodiumhydroxide, calciumhydroxide and other
chemicals. Its tensile strength shall not be less than 35 kg/sq.cm. Its
compressive strength shall not be less than 140 kg/sq.cm ( 7 days) and
350kg/sq.cm (28 days). It shall meet the requirements of IS: 4832 Part-I and
IS: 4443 (latest edition).
7.10.1 General
It covers all works for water proofing with Glass Fibre based Felt of type 2 and
Grade-1 conforming to IS: 7193 –2013 with alternate layers of hot bitumen.
7.10.2 Specification
The minimum weight of glass fiber tissue shall be 40 gm/m 2 and nominal
thickness of 0.5 + 0.1 mm. Blown bitumen shall conform to IS 702:1988 or
residual bitumen conforming to IS 73:1992 may be used as bonding material.
7.10.3 Application
i) Provide suitable slope on the roof (say 1 in 20) with PCC 1:2:4. Heat
insulation shall be provided wherever indicated.
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ii) Clean the surface (to be made waterproof) with wire brush and plaster
with 12-mm thick cement mortar 1:4 (1 cement: 4 fine sand).
iii) Clean the plastered surface and prime with bitumen primer at the rate of
0.4 kg/sq.m.
iv) Apply first coat of hot bitumen @ 1.2 kg/sq.m (min) conforming to IS : 702.
v) Embed the first layer of glass fiber base felt Type-2 Grade-1.
vi) Apply second coat of hot bitumen @ 1.2 kg/sq.m (min).
vii) Embed the second layer of glass fiber base felt type-2 Grade-1.
viii) Apply third coat of hot bitumen @ 1.2 kg/sq.m (min).
ix) Embed the third layer of glass fiber base felt Type-2 Grade-1.
x) Apply fourth coat of hot bitumen @ 1.2 kg/sq.m (min).
The surface should be finished with brick tiles 40 mm thick laid in cement mortar
1:3 (1 cement :3 coarse sand).
7.10.5 Guarantee
A written guarantee for the water tightness shall be given for a minimum period
of 10 years.
7.11.1.1.1 Materials
Steel sections used for fabrication of doors, windows, ventilators etc. shall be
standard rolled sections specified in IS 1038 and IS: 1361. Steel sheets for
frames, shutters etc. shall be of gauge mentioned in this specification. The hot
rolled steel sections shall conform to IS:7452 (latest edition). Fire check doors
shall conform to IS:3614 (latest edition). Hardware and fixtures of the best
quality from approved manufacturers shall only be used.
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Single sheet doors shall be made from best quality 18-G mild steel sheets and
shall present a flush surface on the outside. The inside shall be stiffened with
semitubular edge and central stiffening rail which shall carry the lock and other
fixtures.
Doors shall be mortised, reinforced, drilled and tapped in shop for hinges, locks
and bolts. They shall also be reinforced for closer push-plates and other surface
hardware where necessary. Any drilling and tapping required for surface
hardware shall be done at site.
Wherever required provisions shall be made for fixing glazing, vision panels, etc.
Glazing moulding shall be 18 G steel and suitable for fixing 5.5mm glass.
7.11.1.2.1 The panel inserts shall be 12mm thick solid board made out from seasoned
Deodar wood.
7.11.1.2.2 The stiles and rails of panel doors shall be made out of seasoned Deodar
wood. The size of stiles and rails, lock rails and bottom rails shall be 100 mm
x 35mm. There should be two panels and the center lock rail should be
covered with aluminum sheet on both the sides.
7.11.1.2.3 Paint for priming shall be formulated from basic lead sulphate paste in oil, and
two coats of synthetic enamel paint shall be applied as per clause 1.02.3.
7.11.1.2.4 Fittings for fixtures for doors:
Except otherwise specified or indicated on the drawings, trim and finishes for
fittings shall be as follows:
i) All exposed fittings (namely lower bolts, sliding bolts, butt hinges, door
handles and knobs), other than butts, hinges and door closer shall be of
oxidised mild steel.
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7.11.2.1 Materials
i) Frames and sash for windows and ventilators shall be of standard rolled
steel sections for industrial buildings and shall conform in all respects to
requirements of IS Code 1361 (latest edition).
ii) The windows where openable shall be provided with cam handles 2 Nos.,
tower bolts 2 Nos. and stays 2 Nos. All these fittings shall be of oxides of
iron of appropriate size, quality and shall be subject to the approval of the
Purchaser.
iii) Windows operations, except as otherwise indicated, shall be by means of
cam handles of approved design and construction.
iv) All the windows and ventilators in the ground floor level shall be provided
with MS Grills of approved design.
7.11.2.2 Installation
7.11.2.2.1 Windows shall be set plumb and true, properly aligned and securely anchored
in place.
7.11.2.1.2 Ventilator where openable shall be correctly balanced with uniform tension to
hold ventilator in any open position and they shall be equipped with limit stop
and alignment guides as approved. All ventilators shall be correctly adjusted
before glazing and rechecked after glazing.
7.11.2.1.3 The contractor shall properly protect windows and ventilators during
construction and shall thoroughly clean all plaster, mortar or other foreign
material from them at the completion of all building operation
7.11.2.1.4 All metal in windows and ventilators shall be given a priming coat of red lead
and two coats of synthetic enamel paint of approved quality.
7.11.3 Glass and Glazing Work
7. 11.3.1 Materials
7. 11.3.1.1 Glass shall be of a quality of 4mm thickness 10 kg/m2 clear double strength
conforming to IS: 1761 (latest edition).
7. 11.3.1.3 Glazing compound shall be Bostic single part silicon sealant, which shall be
applied along the periphery of the glass.
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7.11.4.1 The sizes of glass panels and proper edge clearance shall be determined by
measuring the actual unit to receive the glass.
7.11.4.2 The installed glass shall bear the manufacturer's label indicating the type,
thickness and quality of the applied materials.
7.11.4.3 Moveable sections shall be kept closed and locked until glazing compound has
sufficiently set.
7.11.4.4 Upon completion of the works, all glass surfaces shall be thoroughly cleared of
all labels, and other defacement. Cracked, broken and imperfect glass shall be
replaced at no additional cost to the owner.
7.11.4.5 The glasses on all windows and ventilators shall be fixed in such a way. That
then replacement can be done from inside the buildings where they are
provided.
The rolling shutters shall be of mechanically operated type and shall be complete
with hood, guides, springs, bearing etc. Suitable provisions for automatic
tripping of motor/motors in case of jamming or over loading shall be provided. In
case of electrically operated shutters, these shall also be capable of being
operated mechanically by two men. Shutter shall conform to IS: 6248-1971
(latest edition).
7.12.1 Materials
After the sub-grade has been compacted thoroughly, PCC (M-20) topping shall
be laid with thickness (75 mm) of cement concrete floors with a minimum
outward slope of 1 in 48.
The peripheral U-drain shall have a minimum depth of 200 mm at the beginning
and width sufficient to carry the rainwater. It shall have suitable longitudinal slope
and shall be properly linked to the nearest storm water drain. This drain shall
have U-shaped bottom made of PCC (M-20). The side walls of the drain shall be
of brick walls (II class) of suitable height and width in 1:6 cement mortar duly
plastered exposed surfaces (15 mm thick) in 1:4 cement mortar.
7.13.1 Materials
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7.13.1.1 Miscellaneous steel parts shall include all items such as anchor bolts, pipe
sleeves, puddle flange through floors and walls, equipment mounting
plates/frames, steel pieces set in concrete for frames and support frames,
concrete inserts, expansion bolts etc. Miscellaneous steel shall be furnished by
the contractor, detailed and fabricated by him in accordance with the
requirements as indicated in the detailed drawings.
7.14.1 The walls & ceiling shall be provided with Acrylic emulsion paint (interior) of
reputed make over prepared base. The outer face of building shall have peach
colour weather proof acrylic (exterior) paint. Columns, beams parapet and
plastered area shall have mid cream colour whether proof acrylic emulsion
(exterior) paint. All the steel work shall have first quality paints of approved
make/shades. The boundary wall shall be provided with weather proof acrylic
emulsion (exterior) paint. All fire fighting MS pipes shall have post office red colour
paint.
7.14.1.1 Materials
The Acrylic interior emulsion and weather proof exterior acrylic emulsion paints
shall be of superior quality. The material should be brought to site in sealed
condition and stored properly. All paints and allied materials shall be of 1st quality
manufactured by standard firms. and meet the requirements of following Indian
Standards for metallic surfaces and shall be of approved brands and
manufacturer and of approved shade. a) Primer for Iron, steel etc. shall be
conforming to IS: 2074. The primer shall be ready mixed primer. b) Synthetic
enamel paint shall be conforming to IS: 117, IS: 133 and IS: 137 of first quality.
7.14.1.2 Application
Two to three coats shall be applied over a priming coat as detailed below:
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The priming coat shall be done with matching brand by thinning with 100%
volume/weight with clean water followed by two coats of topcoat.
Manufacturer guidelines may be followed.
(iii) Minimum time interval of at least 6 hours maximum upto 7 days shall be
allowed between successive coats to permit proper drying of preceding coat.
b) Painting
(i) All rust & scale be removed by scrapping or by brushing with steel wire brush.
(ii) The primer coat shall be allowed to dry before painting is started.
(iii) The putty around glass panes shall also be painted.
(iv) The additional coats of paint etc. shall be provided if required for the required
finish as per Executive Engineer/ Civil Works Division.
Water proofing cement paint of approved quality and shade and conforming
to IS 5410 shall be used in original. The cement paint shall be brought to site
of work by contractor in sealed containers.
7.14.2.2.2 To avoid cracking and flaking, working in the sunshine shall be avoided. In
dry weather, the surface after application shall be lightly sprayed with water to
keep the surface moist.
7.14.2.3 Application
7.14.2.3.1 The cement paint shall be mixed with water and prepared in accordance with
the manufacturer’s instructions. Only that much quantity of paint shall be
mixed at a time which is sufficient for an hour’s work.
7.14.2.3.2 The paint shall then be applied on the surface by means of brushes in
horizontal and vertical strokes which together shall constitute one coat.
Subsequent coats shall be applied after the previous one has set at least for
24 hours. Before application of second or subsequent coat the surface of the
previous coat shall not be wetted.
7.14.2.3.3 To avoid cracking and flaking, working in the sunshine may be avoided. In dry
weather the surface after application shall be lightly sprayed with water to keep
it wet.
7.14.2 Synthetic Enamel Paint
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7.14.2.1 Materials
The synthetic enamel paint shall conform to IS:2932 (latest edition) for exterior
finish and IS:3537 (latest edition) for interior work.
7.14.2.2.2 Application
(a) UNDER COAT : One coat of specified ordinary paint corresponding to
IS:2932 or IS:2933 (latest edition) suited to shed of top coat, shall be applied
and rubbed with finest grade of wet abrasive to ensure smooth even surface.
(b) TOP COAT : Top finishing coat of synthetic enamel paint of desired shade
shall be applied after the under coat is thoroughly dry.
7.15 TECHNICAL SPECIFICATION FOR GROUTING
7.15.1 General
This the work of grouting of blockouts, foundation bolt holes and space between
bottom of base plate and top of foundation concrete and any other work required
for grouting.
7.15.2 Materials
7.15.2.2 Sand shall conform to the stipulations contained in IS-383 (latest edition) and
shall have a fineness modulus not exceeding 3 and not less than 2.5.
7.15.2.3 Water shall be clean and fresh and shall be of potable quality.
7.15.2.4 Aluminum powder or anti-shrinkage admixture of standard brand from a
reputed manufacturer shall be used. Instead, shrinkomp by ACC Ltd or
equivalent, which is a ready mix concrete containing cement can also be used.
Materials to be used shall be got approved by the Purchaser prior to their use
on work.
7.15.2.5 The blockouts and bolt holes which have to be grouted shall be cleaned
thoroughly by use of compressed air immediately before taking up the grouting
operation.
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7.15.2.6 Grouting shall be adopted for filling blockouts, foundation bolt holes and space
between the underside of base plates and top of foundation concrete. Mortar
made up of cement and sand in the proportion of 1:1 by weight and blended
with aluminium powder (about 0.005% by weight of cement) or anti-shrinkage
admixture in a suitable proportion to the cement mortar in accordance with the
recommendation of the manufacturer and subject to the approval of
Purchaser, shall be used.
7.16.1.2 Steel will conform to grade -A of I.S. 2062 (latest) for rolled steel members or
plates upto 20mm thickness. For plates above 20mm thickness steel
conforming to grade -B (killed and normalized) of IS- 2062 shall be used
except for crane girders where grade-C (IS-2062) steel shall be used. Steel
shall be procured from approved main producers.
7.16.1.3 Chequered plates shall conform to I.S. 3502 and minimum thickness of
chequered plates for flooring, covers etc. shall be 6mm O/P.
7.16.1.4 Shop connections shall be welded and field connections will generally be bolted
unless specified otherwise. Field bolts wherever provided shall be high tensile
bolts of dia 20mm or more. The bolted joints shall be designed for friction type
connection and the HT bolts shall be tightened to develop the required
pretension during their installation. Nominal connections in the field like purlins,
stairs etc. will be done by 16mm dia. M.S. black bolts (minimum property class
4.6) conforming to I.S. 1363. All removable type connection shall be with
bearing type HT bolts of grade 8.8.
7.16.1.5 For all field connections whether welded or bolted, 80% of the shop design
strength shall be considered.
7.16.1.6 Design of connection.
i) Connection of vertical bracings with connecting member and diagonal of
truss members shall be designed for full tension capacity of the member.
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ii) Size of fillet weld for flange to web connection for built up section shall be
as follows.
a) Full shear capacity or actual shear whichever is more for box section.
b) 80% of full shear (if indicated on drawing) or 0.5 times of the web
thickness whichever is more for I – section. The weld shall be double
fillet.
c) All welds shall be continuous. The minimum size of fillet weld shall be
6mm.
d) Shear connection shall be designed for 75% of section strength or
actual shear for rolled sections and 80% of section strength or actual
shear whichever is higher for built up section or rolled section with
cover plates.
e) Moment connection between beam and column shall be designed for
100% of the moment capacity of the beam section.
a) The connection between top flange and web of the crane girder shall be
full penetration butt weld and for bottom flange connection may be fillet
weld.
b) Connection of base plate and gusset members with columns shall be
done considering that the total load gets transferred through weld.
c) Splicing: All splicing shall be full strength. Field splicing shall be done
with web/flange cover plates. For exceptional cases the field splicing
shall be designed for 50% of load carried by cover plates and remaining
50% of load through full penetration butt weld. Shop splicing for all
sections other than rolled sections shall be carried out by full penetration
butt welds with no cover plates. Splicing for all rolled sections shall be
carried out using web and flange cover plates.
7.16.2.2 Test samples shall be cut out of the materials from the location indicated by
the Purchaser and samples shall be prepared in accordance with the
requirements of Indian Standard specification for conducting such tests. For
each set of tests three samples shall be taken for tensile strength test and
bend test.
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7.16.2.3 Copies of all test certificates relating to materials procured by the Contractor
for the works shall be forwarded to the Purchaser.
7.16.4 Fabrication
7.16.4.1 The fabrication works shall be carried out generally in accordance with IS: 800
as well as the stipulation contained in these specifications. All materials shall
be completely fabricated at site fabrication yard and finished with proper
connection materials for ready assembly at erection site.
7.16.4.2 All steel materials shall be straight and free from bends or twists, if the sections
are distorted or twisted during transit, storage etc., they shall be straightened
and/or flattened by straightening machine at ambient temperature though minor
kinks or bends may be corrected by limited heating under careful supervision,
without any extra cost to the Purchaser.
7.16.4.3 The permissible fabrication deviation of structural steel work shall be within the
limits as mentioned in IS:7215 (latest edition).
7.16.5 Bending
The bending of plates and sections to specially required shapes shall be done
either on appropriate machine or by angle smithy and black smithy work carried
out manually on bending plate.
7.16.6 Cutting
Cutting may be effected by shearing, cropping, sawing or by gas cutting by
mechanically controlled torch. Gas Cutting by hand may only be used when
specifically authorised in writing by the Purchaser. The edges of all plates shall
be perfectly straight and uniform throughout. Shearing, cropping and gas cutting
shall be clean squares and free from distortion and burrs and should the
Purchaser find it necessary, the edges shall be ground afterwards by the
Contractor without any extra cost to the Purchaser.
7.16.7 Grinding
All the edges cut by flame shall be ground before they are welded.
7.16.8 Clearance
The erection clearances for cleated ends of members connecting steel to steel
shall not be greater than 2mm at each end unless specifically approved by the
Purchaser, in which case suitably designed seatings shall be provided.
7.16.9 Holes
7.16.9.1 Holes for bolts shall not be formed by a gas cutting process except in
16.12special cases with specific permission of the Purchaser.
7.16.9.2 To facilitate grouting and escape of air holes shall be provided wherever
necessary in column bases.
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7.16.9.3 Wherever a horizontal member is likely to collect water suitable holes for
drainage shall be provided.
7.16.9.4 Contractor shall have to drill holes/set backs for other works connected with
his works at no extra cost.
7.16.10 Notches
The ends of all joist, beams and girders shall be cut truly square unless required
otherwise and joist flanges shall be neatly cut away or notched where necessary
the notches being kept as small as possible. Corners of such notches in flange
shall be shaped to a radius of 50mm.
7.16.11 Assembly
The component parts shall be assembled in such a manner that they are neither
twisted nor otherwise damaged and shall be so prepared that the specified
camber, if any, is provided. In order to minimise distortion in a member the
component parts shall be positioned by using clamps, clips, dogs, jigs and other
suitable means and fasteners (bolts and welds) shall be used in a balanced
pattern. If the individual components are to be bolted, parallel and tapered drifts
shall be used to align the parts so that the bolts can be accurately positioned.
7.16.12 Bolting
7.16.12.1 Every bolt shall be provided with a steel washer under the nut so that no part
of the threaded portion of the bolt is within the thickness of the parts bolted
together.
7.16.12.2 All bolts and nuts shall be of steel with well formed hexagonal heads unless
specified otherwise forged from the solid and shall be dipped in hot boiled
linseed oil as soon as they are made. The nuts shall be good fit on the bolts
and two clear threads shall show through the nut when it has been finally
tightened up.
7.16.13 Stairs, Railing and Ladders
7.16.13.1 All stairs and intermediate landings shall be constructed to size, dimensions
and design, as indicated on the detailed drawings. Each stairway shall be
fabricated as a complete unit which shall include struts, hangers, posts, cross
bracing, cleats and accessories, as required for connection to structural steel
framing and concrete.
7.16.13.2 Gratings for stair treads and landings shall be of rectangular pattern to match
floor grating as specified.
7.16.13.3 Stair treads shall be furnished complete with punched and slotted carrier
plates attached ready to bolt to stair stringers tread shall be provided with an
approved type anti-slip nosing set flush with the stair tread.
7.16.13.4 Grating treads and gratings for landings of interior stairs shall be paint finished
as specified for floor gratings.
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7.16.13.5 Pipe hand rails, as specified in detailed drawings, shall be assembled with
flush type fittings and welded joints, ground and polished smooth. Railings
shall be provided with all necessary fittings, posts, brackets bolts, plates and
similar accessories and shown on the approved drawings and as required for
proper installation.
7.16.13.6 Vertical ladders shall be as called for on the approved drawings. The ladders
shall be provided with support arms formed of bend steel plate or chip angles.
Where shown on the drawings, the ladders shall have loose neck supports
designed to form hand grabs and end brackets for fastening to abutting
construction. Maximum deviation in the linear dimensions of railing, stairs and
ladders from the approved dimensions shall not exceed 12 mm.
7.16.14 Foundation Bolts
7.16.14.1 Foundation bolts shall be embedded in first stage concrete. The bolts
shall preferably be provided in pipe sleeves permitting adjustments in
the proper alignment of these bolts to match holes in the column bases
otherwise templates shall be used for proper alignment of the bolt. The
grouting shall be carried out after second stage concrete.
7.16.14.2 The contractor shall be responsible for the correct alignment and levelling of
all steelwork on site and to ensure that the columns are in plumb. The
permissible erection tolerances for the structural members shall be as given
in the table below:
+ 5 mm.
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7. 17.1.1 Sand shall be clean and free from dust, organic and foreign matters subject to
approval of Purchaser.
7.17.1.2 The spaces for filling shall be cleaned of all debris, bricks bats etc. The filling
shall be done in layers not exceeding 20 cm each layer. Consolidation of each
layer shall be done by flooding with water. The surface of the consolidated
sand shall be dressed to required level or slope. Concreting of floor above
sand filling shall not be started till the Purchaser has inspected and approved
of the sand filling.
7.18.1 General
This covers the installation of the various pipes, viz. (i) rain water pipes, (ii) water
supply pipes and fittings (comprising of GI pipes and sockets, Brass fittings) (iii)
cast iron and spun iron pipes and fittings, (iv) Stoneware pipes and (v) concrete
pipes for catering to the requirements of internal and external arrangement for
water supply and drainage in buildings/structures as specified.
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7.18.2.1 All materials shall conform to the relevant IS specifications. Samples of all
materials, before actual use, shall be shown to the Purchaser and got approved
by him.
7.18.2.2 Before installation of the pipes and their fittings the contractor shall submit his
plans and drawings for execution of the job, which shall be got approved by him.
The installation procedure as prescribed in I.S. specification shall be followed.
Rain water pipes shall have lead jointing.
All pipes and their fittings installed shall be tested as per relevant IS
specifications in the presence of Purchaser or his representative and the test
results submitted to him for approval.
All soil pipes, waste pipes and vent pipes and all other pipes when above
ground shall be approved gas tight by a smoke test conducted under a
pressure of 25 mm of water and maintained for 15 minutes after all trap
seals have been filled with water. The smoke is produced by burning oily
waste or tarpaper or similar material in the combustion chamber of a smoke
machine. Chemical smokes are not satisfactory.
Cast iron pipes shall be subjected to a test pressure of at least 1.50 M head
of water at the highest point of the section under test. The tolerance figure
of two litters per centimeters of diameter per kilometer may be allowed
during a period of 10 (ten) minutes. The test shall be carried out by suitably
plugging the low end of the drain and the ends of connection, if any, and
filling the system with water. A knuckle bend shall be temporarily jointed in
at the top and at a sufficient length of the vertical pipe jointed to it so as to
provide the required test head or the top end may be plugged with a
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Allowance shall be made for by adding water until absorption has ceased and
after which the test proper should commence. Any leakage and the detective
part of the work shall be cut out and made good.
7.21.1 General
This covers the cleaning, preparation and painting of all surface requiring field
painting and finishing in accordance with the schedule drawings.
7.21.2 Materials
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7.21.3.6 Plaster surfaces to be painted shall be smooth and dry, free of dusting and
crevices shall be filled with patching plaster.
7.21.3.7 Concrete surfaces to be painted shall be thoroughly cured, and shall be dry
and free of dust, loose particles and foreign material. The surface shall be
brushed with stiff fibre brush before painting.
7.21.4 Application
7.21.4.1 Painting operations shall not be proceed until the Purchaser has the
opportunity to inspect the condition of the prepared surface to be pained.
7.21.4.2 Prime coat, Intermediate and finish coats of paint shall be applied in strict
conformance with the manufacturer’s printed directions. Paint shall be
thoroughly mixed and not more than ½ Kg of recommended thinner per 4.5
litres of paint shall be added if thinning is necessary.
7.21.4.3 Brushes and paint containers shall be kept clean. Exterior painting shall not
be performed during periods of inclement weather. Interior painting may
proceed during such periods only with the approval of the Purchaser.
7.21.4.4 All painting shall be done as per Manufacturer’s Specifications.
7.21.4.5 The contractor shall prepare and submit samples step-by-step representative
of the quality of the work that he is to perform, for approval of the Purchaser.
Each sample shall be divided into equal parts of size large enough to be used
for comparison with the actual work performed.
7.21.5 Clean-Up
The contractor shall remove all equipment, un-used material and debris resulting
from painting operations and shall leave the site in a condition acceptable to the
Purchaser.
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All demolition/dismantling work shall be carried out in conformance with the local
safety regulations as per IS – 4130 and extreme caution being exercised to avoid
damage to the work and the equipment, which is to be left intact. Necessary
precautions shall be taken to keep the dust nuisance down.
7.23.1 General
7.23.1.1 Block Foundation/ Frame Foundation with Vibration isolation system may be
provided for HT voltage drives viz. booster fans, limestone crushers, mills, slurry
recirculation pumps etc.
7.23.1.2 The vibration isolation system supplied should be of proven make. The bidder
should have designed spring supported machine foundations, manufactured,
supplied and installed vibration isolation system consisting of steel helical spring
units (conforming to DIN 2096 & DIN 2089) and viscous dampers (providing
damping resistance in all three planes) for not less than 25 (twenty five) machine
foundations of heavy rotating machine systems. All the foundation systems
should be in successful operation (without replacement) for at least three years
as on the date of bid opening.
7.23.1.3 Individual spring units supplied should have load carrying capacities ranging
from 100 KN to at least 1000 KN. The largest spring units supplied should have
a load carrying capacity of not less than 1000 KN. The spring units have stiffness
in both vertical and horizontal directions with the horizontal stiffness not less than
50% of vertical stiffness. The stiffness should be such that the vertical natural
frequency of any spring unit at its rates load carrying capacity is not more than
3 Hz.
7.23.1.4 The damper units or spring-cum-damper units should be of viscous type offering
velocity proportional damping. The damper units should be suitable for
temperatures ranging from 0 to 50o C. The damping resistance of individual
damper units should be such that the designed damping can be provided using
reasonable number of units. The bidder should be able to supply damper units
with damping resistance ranging from 40 kN Sec/m to 750 kN Sec/m.
7.23.1.5 In case of elevated foundations such as pedestals/walls, the sizes of the spring
units, damper units and spring-cum-damper units should be such that groups of
such units can be accommodated on the top of these pedestals/walls.
7.23.1.6 The bidder shall furnish information about the entire range of spring units,
damper units and spring-cum-damper units manufactured by him to enable the
owner to do the engineering. The information to be furnished should include the
load carrying capacity, stiffness (vertical & horizontal), damping resistance, and
dimensions of spring and damper units.
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Latest revisions of the following codes shall be used for the design of the
spring supported foundations:-
a) Steel helical spring units and viscous damper alongwith viscous liquid
including associated auxiliaries for installation of the spring units and
dampers like steel shims, adhesive pads, etc.
b) Frames for prestressing of spring elements.
c) Suitable hydraulic jack system including electric pumps, high pressure
tubes etc. required for the installation, alignment etc. of the spring . One
set of extra hydraulic jacks, and hand operated pumps shall also provided.
d) Any other items which may be required for the complete installation for
satisfactory commissioning of the spring system.
7.23.5 Documentation
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v) A check list for conforming the readiness of the civil fronts for installation of
vibration isolation system and equipments required at each stage of
installation.
vi) Bill of materials of various elements such ash spring units, viscous
dampers, with their rating, stiffness etc. included in the supply
vii) Any other details which Owner/Consultant may consider necessary to
facilitate design and construction of the foundations/structures.
All the equipments shall be suitably protected, coated, covered or boxed and
crated to prevent damage or deterioration during transit, handling and storage at
site till the time of erection. While packing all the materials, the limitations from
the point of view of availability of railway wagon sizes, in India should be taken
into account. The contractor shall be responsible for any loss or damage during
transportation, handling and storage due to improper packing.
If any realignment of the spring system is required to be done for aligning the
shaft or for any other reasons during the first one year of operation from the date
of commissioning the same shall be done by the contractor without any cost to
the Purchaser.
The contractor shall guarantee the performance of the vibration isolation system
for 24 months from the date of commissioning of each machine which shall be
termed as “Guarantee Period”.
The spring supported foundation shall be designed for a minimum operating life
of 30 years.
7.24 TECHNICAL SPECIFICATION FOR PRE-CAST RCC SLABS
7.24.1 General
7.24.1.1 The precast ribbed slabs shall be manufactured at the project site for which
adequate area will be given free of charge. The contractor shall arrange at his
own cost necessary sheds etc. for casting, arrange for necessary facilities
during and after manufacture, provide the sufficient handling equipment for
curing in curing tanks the cast pieces and for stacking.
7.24.2 Materials used shall conform to those for cement concrete described elsewhere
in this Section.
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7.24.3.1 The concrete mix. shall conform to IS 456 (latest edition) for concrete. The
compressive strength as measured by strength test at 28 days shall be as
indicated on the drawings for different pieces of construction.
7.24.3.2 Aggregates shall be mixed by weight and the water cement ratio shall be
controlled so as to obtain the densest concrete and the strength required.
7.24.3.3 The forms for the pre cast elements shall be made up of steel of sufficient
thickness so as to be rigid and obtain a smooth surface after the forms are
struck. The contractor shall submit detailed drawings of form work for the
approval of the Purchaser. Finishing with the cement mortar shall not be
allowed. Vibration shall be carried out with form vibrators mounted on to form
work. In addition, rodding shall be done to ensure that the concrete material
is evenly spread and fills all inaccessible regions. Nothing extra shall be paid
for form work.
7.24.3.4 Curing shall be carried out for a period of seven days from the day of casting.
7.24.4 Bending and placing of reinforcement shall be as described for cement concrete
elsewhere in this Section.
Structural steel in the form of angles, flats etc. which shall be supplied, fabricated
by the Purchaser within the project area shall be transported and embedded in
position in various pre cast members to correct lines and levels by means of
welding or otherwise as indicated in the detailed working drawings.
7.24.7.2 The pre-cast elements shall be welded in position to the structural steel by
means of matching pieces embedded already in the pre cast element.
7.24.7.3 The space between adjacent pre cast slabs shall be filled with cement
concrete of suitable grade (a grade higher than that of the pre cast elements).
The W/c ratio shall be kept to the minimum. It shall be as directed by the
Purchaser.
7.24.7.4 After the erection of the pre cast pieces at site, the hooks provided for lifting
purposes shall be cut flush to the surface of the slab.
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The work described herein shall cover providing and installing metal sheet
roofing and cladding including translucent sheets and all accessories such
as flashings, cappings, gutters, trims, supporting straps, brackets, foam
fillers, sealants and the work shall be carried out strictly in accordance with
this specification and applicable drawings.
7.25.2 Materials
High tensile Galvalume (AZ 150 gsm) SMP colour coated (in approved colour)
or equivalent profile shall be used. Total coat thickness (TCT) of sheets shall
be minimum 0.55 mm with base metal thickness without any coating shall be
minimum 0.50 mm with minimum yield stress 550MPa.
Galvalume sheets shall conform to AZ 150 gsm of AS 1397 or ASTM 792 with
hot-dip metallic coating of 55% Al and 45% Zn alloy having total coating mass
of min. 150 gms/m2 inclusive of both sides.
The colour to be used for coating shall be intimated.
Roof extractors shall be fixed in position as per approved drawings. The work
shall include making required opening in the sheeting, fixing the extractors
as per the manufacturer’s instructions with necessary fasteners. Lead fillers,
felts or any other specified flashing shall be tucked into the sheeting. The
lead flashings used shall be weighing not less than 30 Kg/sq. meter.
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7.25.6 Accessories
Materials and coatings for ridge capping, barge capping, apron flashing,
cover flashing, monitors and expansion joints shall be manufactured out of the
same material as roofing / cladding sheets material and shall be shaped to
match sheet profile.
7.26 TECHNICAL SPECIFICATION FOR G.I. ROOF & SIDE SHEETING AND
ACCESSORIES
7.26.1 General
This covers the general requirements for G.I.sheeting for roofing and side
cladding including all accessories and fixtures.
7.26.2 Materials
7.26.2.1 Galvanised steel corrugated sheets shall be hot dipped galvanized conforming
in all respects to IS : 277 with a coating of grade 750.
7.26.2.2 The galvanized sheets shall be of the thickness, as specified and shall be of
approved quality and manufacture as approved by Purchaser.
7.26.2.3 The sheets shall be free from cracks, pitting, blisters, split edges, twists,
laminations, scales and other surface defects. Sheets shall be clearly sheared
and be free from twist or buckle and shall have uniform corrugations, true in
depth and pitch parallel to the sides of the sheet. The galvanized coating shall
be clean, bright, smooth and free from ungalvanised spots and other defects.
The sheets supplied shall show no sign of rust or white powdery deposits on the
surface.
7.26.3.1 Sheets shall be stacked to a height of not more than one metre on firm
and level ground, with timber or other packing beneath them.
7.26.3.2 Galvanised steel materials of same variety and size shall be stacked together.
7.25.3.3 All galvanized materials shall be protected from damage while stored on site
preferably in sheltered store. If they are to be placed in an exposed position,
they shall be protected from damage by wind and rain by providing a suitable
cover.
7.26.3.4 Contractor shall exercise great care in handing the sheets and accessories.
Damaged material shall not be stacked with sound materials. All damaged or
rejected materials shall be removed from site immediately.
7.26.4 Laying
7.26.4.1 The sheets shall be laid on the purlins/other roof members and side girts as
indicated on the drawings or as instructed by Purchaser
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7.26.4.2 The maximum spacing of purlins shall be 2 m, 1.8 m and 1.6 m for sheets of
1.0mm, 0.8 mm and 0.63 mm thickness respectively.
7.26.4.3 Before the actual laying of sheets is started, the purlin spacing and the length
of the sheets shall be checked to ensure proper laps and the specified overhang
at the eaves. The end lap of the sheets shall always fall over a purlin/side girt.
7.26.4.4 The bearing surface of all purlins/other roof members and side girts shall be in
one plane so that the sheets being fixed shall not be required to be forced down
to rest on the purlins/side girts. The finished roof shall present a uniform slope
and lines of corrugations shall be straight and true and the completed work shall
present a neat and uniform appearance and be leak proof. For side sheeting,
corrugation shall be vertical and in one plane.
7.26.4.5 The sheets shall be laid with a minimum lap of 150 mm at the ends and 2 ridges
of corrugations at each side. In the case of roofs with a pitch flatter than 22
degrees or in the case of very exposed situations, minimum end laps shall be
200 mm. The side laps shall be laid on the side facing away from the prevailing
monsoon winds. The minimum lap of sheets with ridges, hips and valleys shall
be 200 mm measured at right angles to the line of ridge, hip or valley
respectively. The free overhang of the sheets at the eves shall not exceed 300
mm.
7.26.4.6 The sheets shall be cut to suit the dimensions or shape of the roof, either along
their length or their width or in a slant across their lines of corrugations at hips
and valleys. They shall be cut carefully with a straight edge and chiseled to give
a smooth and straight finish. The corrugated galvanized sheets shall not
generally be built into gables and parapets. They shall be bent up along their
side edges close to the wall and the junction shall be protected by suitable
flashing or by a projecting drip course covering the junction by at least 75 mm.
7.26.4.7 Where slopes of roofs are less than 22 degrees, sheets shall be joined together
at the side laps by galvanized iron seam bolts and nuts of size 25 mm x 6 mm,
each bolt with a bitumen and G.I.limpet washer or with a G.I. limpet washer filled
with white lead. The seam bolts shall be placed zigzag over the two overlapping
corrugations at a spacing nor exceeding 600 mm along each of the staggered
rows.
7.26.4.8 All laps in G.I. sheets shall be painted with one coat of zinc rich primer and
two coats of approved paint before fixing in place.
7.26.5 Fixing
7.26.5.1 Sheets shall be secured to the purlins and other roof members by means of 8
mm diameter galvanised iron J or L hook bolts and nuts with bitumen and G.I.
limpet washer or with a G.I. limpet washer filled with white lead, as directed by
Purchaser. The grip of the hook bolt on the side of the purlin shall not be less
than 25 mm. Each hook bolt shall have a bitumen washer and a galvanised iron
washer placed over the sheet before the nut is screwed down from above. There
shall be a minimum of three hook bolts placed at the ridges of corrugations in
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each sheet on every purlin and spacing shall not exceed 300 mm. Bitumen
washer 35 mm in dia. and 1.5 mm thick shall be of approved manufacture. Each
nut shall be screwed lightly at first. After 10 or more sheets are laid, the nuts
shall be tightened to ensure a leak proof roof. The bolts shall be sufficiently long
so that after fixing they project at least 12 mm above the top of their nuts.
7.26.5.2 Where sheets are laid on tubular purlins, the fixing bolt shall be designed to
encompass at least half the tube circumference and precautions should be taken
to prevent its rotation.
7.26.5.3 Holes for hook bolts etc. shall be drilled and not punched in the ridges of the
corrugations in the exact positions to suit the purlins while the sheets are on the
ground. The diameter of holes shall be 1.5 mm more than the diameter of the
fixing bolts, while the holes in the washers shall be of the exact diameter of the
hole bolts or the seam bolts. No hole shall be nearer than 40 mm to any edge
of a sheet or an accessory. Sheets with holes drilled wrongly shall be rejected.
7.26.5.4 Direct fixing of sheets to drilled steel frame work or by stud welding or fixing by
coach screws shall not be permitted.
7.26.6.1.1 Ridges and hips of corrugated galvanised roofs shall be covered with ridge
and hip sections of plain G.I. sheets with a minimum 200 mm lap on either side
over the C.G.I. sheets. The end laps at the ridges and hips and between ridges
and hips shall also be not less than 200 mm. The ridges and hips shall be of
600 mm overall width made from plain G.I. sheets, 0.6 mm or 0.8 mm thick,
bent to shape and fixed as shown on the drawings.
7.26.6.1.2 Ridges and hips shall be fixed to the purlins below with the same 8 mm dia.
G.I. hook bolts and nuts and bitumen and G.I. limpet washers, which fix the
sheets to the purlins. At least one of the fixing bolts shall pass through the end
laps of ridges and hips, on either side. If this is not possible extra hook bolts
shall be provided.
7.26.6.1.3 The end laps of ridges and hips shall be joined together by G.I. seam bolts
25 x 6 mm size each with a bitumen and G.I. limpet washer. There shall be at
least two such bolts in each end lap.
7.26.6.1.4 The edges of the ridges ad hips shall be straight from end to end and their
surfaces shall be plane and parallel to the general plane of the roof. The ridges
and hips shall fit in squarely on the sheets and shall be leak proof.
7.26.6.2.1 Valleys shall be 900 mm wide overall made from plain G.I. sheet 1.6 mm thick
bent to shape and fixed as shown on the drawings or as directed by Purchaser.
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Section-7 (Civil Works)
Laps with C.G.I. sheets shall not be less than 250 mm on either side. The end
laps of valleys shall also not be less than 250 mm.
7.26.6.2.2 Flashing shall be of 1.25 mm thick or 1.00 mm thick plain G.I. sheet having
400 mm overall width, bent to shape and fixed as shown on the drawings. They
shall lap not less than 150 mm over the roofing sheets. The end laps between
flashing pieces shall not be less than 250 mm.
7.27.2 Materials
7.27.2.1 Aluminium alloy used in the manufacture of extruded sections for the fabrication
of doors, windows, ventilators shall conform to designation HE9-WP of IS:733.
7.27.2.2 Transparent sheet glass shall conform to the requirements of IS:2835. Wired
and figured glass shall be as per IS:5437.
7.27.2.3 Builder’s hardware of fittings & fixtures shall be from vendors approved by the
Purchaser.
7.27.3 Workmanship
7.27.3.1 The doors, windows, ventilators shall conform to the requirements of IS:1948.
Aluminium windows, shall conform to IS: 1949, if so specified.
7.27.3.2 All aluminium units shall be supplied with anodized finish. The minimum anodic
film thickness shall be 0.015 mm.
7.27.3.4 Aluminium swing type doors, aluminium sliding windows, partitions shall be as
described in the item of work and/or bid drawings which indicates generally the
arrangement along with the overall size of the various components and weight
per running metre of the extruded sections to be adopted.
7.27.3.5 IS:1948 and IS:1949 referred to incorporate the sizes, shapes, thickness and
weight per running metre of extruded sections for the various components of the
units. However, new sizes, shapes, thickness with modifications to suit snapfit
glazing clips etc. are continuously being added by various leading manufacturers
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Section-7 (Civil Works)
of extruded sections, which are available in the market. As such, the sections of
the various components of the unit proposed by the Contractor will be reviewed
by the Purchaser and will be accepted only if they are equal to or marginally
more than that specified in the codes.
7.27.3.6 The framework of the partitions with mullions and transoms shall be with
anodized aluminium box sections of dimensions as per the item of work.
Anodised Aluminium box sections shall be in-filled with timber of class 3 (silver
oak or any other equivalent) as per IS: 4021. Panels of double/single
glazing/plywood shall be fixed as per details indicated in the drawing. Partitions
shall be fixed rigidly between the floor and the structural columns/beams
including provision of necessary shims for wedging etc. Finished work shall be
of rigid construction, erected truly plumb to the lines and levels at locations as
per the construction drawings.
i) Design Criteria
For chimney with brick lined flue, the thickness of brick wall is generally 230
mm & internal platforms shall be provided at 10m interval.
The chimney flues shall be made of mild steel/ corrosion resistant steel,
with mineral wool insulation secured by G.I .Chicken wire mesh to insulate
whole exterior of the flues.
The design & construction of steel chimney liners shall be based on the
guidelines of EPRI Revised Wet Stack Design guide.
The steel flues shall be supported from floor at elevation 6M below chimney
top and restrained laterally and also at several levels by access/ restrained
platforms. Corrosion allowance shall be considered over structural
considerations. The chimney roof shall be of reinforced concrete & with
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section-7 (Civil Works)
Provision of chimney ventilation and rack & pinion elevator in the chimney
is to be made. The rack & pinion elevator of load carrying capacity of 400kg,
cabin floor size of approximately 1100mm x 1000mm and an operating
speed of 40m/min, shall be provided.
Opening in the Chimney shell shall be provided for duct work, access door
etc. The total plan area of openings at a particular section shall not be more
than 15% of plan area of concrete shell at that location. The maximum
width of opening shall be limited to an angle of not more than 30 degree
subtended at center of concrete shell. The extra reinforcement around
opening shall be calculated as per the following criteria and maximum
reinforcement obtained out of the three criteria shall be provided:
a) IS – 4998
b) ACI – 307
c) Reinforced concrete chimney and tower by Geoffrey M. Pinfold.
The value of k shall be taken as 0.11 as per data on page No. 186 of
reference at (c) above.
Minimum half the number of extra horizontal bars in shell around the
opening to continue for circle round both faces and both sides.
ii) Materials
All material shall conform to IS Codes. However, the following shall apply:
The flue duct shall be lined with Borosilicate glass block or 2 mm thick
Titanium (Grade 2 as per ASME SB265) or C-276 alloy. Cladding shall be
done to achieve the required quality as per ASTM B 898-11. External
surface of chimney flue liner projecting over the chimney roof shall be
wrapped with 2 mm thick Titanium / C-276 sheet over insulation.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section-7 (Civil Works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section-7 (Civil Works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section-7 (Civil Works)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section-7 (Civil Works)
The final design shall be checked & verified by ‘Wind Tunnel Test’.
Dynamic interference effects due to additional chimney(s) located in the
area or in future expansion shall be determined along with the other
topographical features of the local area through model test.
Internal and external platforms is generally provided at 45 m intervals.
Internal platforms will be of structural steel supported over RCC shell. A
Structural steel staircase is provided to access platforms.
An opening in windshield at ground level shall be provided for installation
of flue with suitable door for access of personnel & trucks. Aviation
obstruction lighting for warning aircraft of chimney obstruction shall be
provided.
xix) Basis of design
The reinforced concrete twin flue chimney is designed in accordance with IS
4998:2015 and “Criteria for design of Reinforced concrete chimney for reference
ACI-307-1979” “specification for design & construction of reinforced concrete
chimney” for items not covered in Indian /CICIND Code (International Committee
for Industrial Chimneys).
The chimney shell is modeled as Beam elements made of annular conical
sections of appropriate diameter and thickness. Chimney foundation shall be in
concrete grade M-25 with minimum cement content of 400 kg/cu.m & wind shield
shall be grade M-30 with minimum cement content 425 kg/cum. 43 Grade OPC
for concrete foundation & shell be used.
xx) Loading and their combinations
Dead load:- All permanent loads due to weight of chimney shell, internal platforms
and lining supported on them, ladders, flue ducts, staircase etc.
Imposed load:-
i) Imposed load on service platform around chimney shall be 500 kg/sqm &
design live load shall be 750 kg/sq.m during construction / erection.
ii) Imposed load from ducts joining the chimney shall also be considered.
xxi) Analysis
Calculation of natural frequencies and mode shape shall be carried out. For this
purpose chimney shaft is idealized as vertical cantilever with limited masses at
different nodes. These nodes shall be provided at each platform. Minimum five
modes shall be considered for calculation of natural frequency and amplitude.
Wind Loads :-
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section-7 (Civil Works)
General:
Wind load shall be calculated as per clause 5.5 of IS 4998:2015 and IS 875
(Part3). Dynamic analysis shall be carried out and stability ensured under
such conditions.
The circumferential ring moments due to wind and wind effect on chimneys
shall be calculated as per clause 5.5.11 of IS 4998:2015.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
SECTION 8.0
MANDATORY SPARES
8.1 Mechanical
2. Booster Fans
i) Fan rotating element including impeller 1 Set
& shaft
Fan bearings 2 Sets
ii) Motor bearings 2 Sets
iii) Oil rings/seal/gaskets/packings/ bushes, 4 Sets
metallic rings
iv) Nuts and bolts 2 Sets
v) Couplings between fan and motor 1 no.
vi) Fan Blades (in case of axial fans) 1 Sets
vii) Inlet guide vanes (IGV) (in case of radial 1 Set
fans)
viii) Casing and impeller wearing elements) 1 Set
(in case of radial fans)
ix) Lube oil system
a) Pump assembly 1 nos. of each type
b) Pressure regulator 2 nos.
c) Filters 4 Sets
d) Coupling for oil pump & motor 1 no.
e) Oil coolers 1 Set
Wet limestone absorber system
4. Nozzle, Piping, Lining etc.
i) Nozzles for limestone slurry spray 10% of total requirement for
both the absorber
ii) Mist eliminator 10% of total requirement for
both the absorber
iii) Mist eliminator wash nozzles 10% of total requirement for
both the absorber
iv) Water distribution piping & other 10% as required for both the
internals absorber
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 8 (List of Mandatory Spare Parts)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
10. Pulleys
i) Drive pulley without bearings and 2 Nos.
plummer blocks
ii) Non drive pulley without bearings & 4 Nos.
plummer blocks
iii) Spherical roller bearings for pulleys of 3 Nos. for each size
different sizes without plummer blocks
iv) Plummer blocks complete with bearings 2 Nos. of each type & size
& sleeves
11. Carriage wheel assembly
i) Bearings 2 Nos. of each size and type
ii) Plummer block 2 Nos. of each size and type
iii) Oil seals 2 Nos. of each size and type
iv) Carriage wheel with shaft (without 1 Set
plummer blocks)
v) Transverse drive assembly including 1 Set
motor, gear box, coupling etc.
12. Gear Couplings
i) Complete gear couplings 2 Nos. of each size and type
ii) Bolts & nuts 2 Sets
iii) Seal kit 2 Sets
13. Fluid Couplings
i) Complete fluid coupling 1 Nos. of each size and type
ii) Multi disc assembly 4 Nos. of each size and type
iii) Bearings 1 Set for each size and type
iv) Seal kit 2 Sets for each size and
type
v) Resilient drive plate assembly 2 Nos. of each size and type
vi) Fusible plugs 10 Nos. of each size and
type
vii) Complete actuator assembly including 1 Nos. of each size and type
motor, gear box etc.
viii) Oil filters 5 Nos. of each size and type
14. Gear Boxes
i) Bearings 1 Set for each type and size
ii) Oil seal for gear box 2 Sets
iii) Worm/Pinion for gear box 1 No. of each size
iv) Bolts for gear coupling 1 Set for each size
v) Complete gear box assembly 1 No. of each type & rating
15. Belt Cleaner & Skirt Board
i) Modular segments for belt cleaner 10% of total population for
each type & size
ii) Modular segments for skirt board 10% of total population for
each type & size
iii) Skirt rubber 10% of total population for
each type & size
iv) Complete belt cleaner (internal/ 5% of total population for
external) each type & size
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
40. Air Drying Plant (Twin tower type ) for IA System (as applicable)
i) Pre filter element (ceramic candle or as 2 Sets
applicable)
ii) After filter element (ceramic candle or as 2 Sets
applicable)
iii) Heater element (if applicable) 1 Set
iv) Blower bearing (if applicable) 1 Set
v) Blower motor bearing (if applicable) 2 Sets
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
341
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
Note:
i) Wherever quantity of spares have been defined in percentage, the quantity shall
be rounded off to next higher integer in case of fractions.
ii) Wherever quantity of spares has been defined in ‘Set’, it shall mean the quantity of
spares to be supplied for one complete replacement for one equipment.
iii) In the case of spares offered in ‘Sets’, the details of each Set giving the number of
parts in the Set shall be clearly mentioned.
iv) In case of any equipment being supplied is of different type/ design, the list of its
spares and their quantities to be supplied shall be as mutually agreed and
approved by purchaser during detailed engineering.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
8.2 Electrical
Sl. No. Description Quantity
1 11/6.6/3.3 kV Switchgears
a) Breaker pole of each rating 1 Set
b) Spring charging motor complete of each type 1 No.
c) Shunt trip coil of each type 1 No.
d) Closing coil of each type 1 No.
e) Current transformer of each type 1 No.
f) Potential transformer of each type 1 No.
g) Protective relay of each type 1 No.
h) Anti-pumping relay of each type and rating 1 No.
i) Auxiliary relays of each type 1 No.
j) Lock out relays of each type 1 No.
k) Timers of each type 1 No.
l) Moving contact assembly of each installed rating 1 Set
m) Stationary (fixed) contact 1 Set
n) Bus seal-off bushings of each type 1 No.
o) Busbar support insulators 5% of total population
s) Control switches of each type 1 No.
t) Selector switches of each type 1 No.
u) Isolation switch for the control supply of each 1 No.
type
v) Operating mechanism rod for each rating 1 No.
w) Set of gaskets of each rating 2 Sets
x) Ammeter of each type and range 1 No.
y) Voltmeter of each type and range 1 No.
z) Indicating lamps 10 Nos.
aa) Indicating lamp covers of all colours, lamp 10% of installed quantity
resistors and holders
ab) Fuse base and holder of each type and rating of 1 Nos.
each type
ac) Fuse of each rating of each type of each type 2 Nos.
ad) Maintenance tools and accessories for 1 Set
maintenance
ae) Isolating contact (Fixed and moving) of each 1 Set
rating
af) Terminal blocks 2 Nos.
ag) Contactors with HRC fuses of each type and 10%
rating
ah) Auxiliary contactors of each type and rating 10%
ai) Control supply transformers of each type 1 No.
aj) Breaker Trolley with each panel 1 No.
2 11/ 6.6/ 3.3kV Segregated Phase Busducts
a) Bus insulators of each type and rating 2 Nos.
b) Set of seal-off bushings of each type and rating 1 Sets
c) Set of 3 phase, Aluminium flexibles 1 Sets
d) Set of 3 phase, copper flexibles 1 Sets
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
346
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
Note:
i) Wherever quantity of spares have been defined in percentage, the quantity shall
be rounded off to next higher integer in case of fractions.
ii) Wherever quantity of spares has been defined in ‘Set’, it shall mean the quantity of
spares to be supplied for one complete replacement for one equipment.
iii) In the case of spares offered in ‘Sets’, the details of each Set giving the number of
parts in the Set shall be clearly mentioned.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
1 Measuring Instruments
i) Electronic transmitters
a) Transmitters of all types, ranges 10% or 2 no. of each type and
and model no. (for the model, whichever is more
measurement of Pressure,
differential pressure flow, level,
etc.)
b) Electronic cards / PCB’s for each 10% or 5 nos. of each type,
type and whichever is more
model and model of transmitters
ii) Temperature elements
a) RTDs* of each type & length 10% or 2 nos. whichever is more
b) Thermocouples of each type like 10% or 2 nos. whichever is more
K-type, R-type, metal etc. and
length *
c) Cold junction compensation boxes 10% or 2 nos. whichever is more
of each model
d) Thermostatic units for each model 10% or 2 nos. whichever is more
of CJC box
* (With head assembly, terminal block
and nipple)
iii) Local Indicators like temperature, 5% or 1 no. of each make, model
pressure, differential pressure, flow and type whichever is more (to
gauges and flow meters etc., be divided to various ranges in
proportion to main of all make,
model, type population)
iv) Process actuated switch devices 5% or 1 no. of each type and
Including all types of pressure, model whichever is more
differential pressure, flow,
temperature, differential
temperature, level switch devices
v) Level transmitters (displacer type)
Electronic cards / PCB’s of level 5% or 1 no. whichever is more for
transmitters each type and model.
Level transmitters 5% or 1 no. of each type,
displacer length and model
whichever is more
vi) PD type flow transmitters 5% or 1 Set of each type and
model whichever is more
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 8 (List of Mandatory Spare Parts)
ii) 2 way, 3way, 5way valve manifolds 10% or 2 no. of each type, class,
size and model whichever is
more
iii) Fittings 10% or 2 packet of each type,
class, size and model whichever
is more.
iv) Purge meters 10 % of each model or 2 Nos.
whichever i
v) Filter regulators 10 % of each model or 2 Nos.
whichever is more
4 Electrical Actuators
i) Actuators 10% or 2 no. of each type, model
and rating, whichever is more
ii) Power unit for modulating actuator 10% or 2 nos. of each type,
whichever is more
iii) DC-DC unit/power pack units 10% or 2 nos. of each type,
whichever is more
iv) Electronic cards 10% or 5 nos. of each type,
whichever is more
v) Brake assembly 10% or 2 nos. of each type,
whichever is more
vi) Brake coils 10% or 2 nos. of each type,
whichever is more
vii) Position feedback transmitters 10% or 2 nos. of each type,
whichever is more
viii) Control unit 10% or 2 nos. of each type,
whichever is more
ix) Torque and limit switch assembly 10% or 2 nos. of each type,
whichever is more
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 8 (List of Mandatory Spare Parts)
Note:
i) Wherever quantity of spares have been defined in percentage, the quantity shall
be rounded off to next higher integer in case of fractions.
ii) Wherever quantity of spares has been defined in ‘Set’, it shall mean the quantity of
spares to be supplied for one complete replacement for one equipment.
iii) In the case of spares offered in ‘Sets’, the details of each Set giving the number of
parts in the Set shall be clearly mentioned.
*******
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
SECTION 9.0
b) For resin bonded mineral wool insulation, testing shall be carried out
as per IS: 8183.
c) For resin bonded rock wool insulation, testing shall be carried out as
per IS: 9842.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
9.1.1.3 Dampers
ii) Gas tight dampers shall be subjected to shop leakage test to demonstrate
the guaranteed tightness (minimum one damper of each type and size
offered). In case such type test is already done, the reports of the same
shall be submitted for review.
9.1.2 Absorber
9.1.2.1 Metal Structures
i) Only material which has been identified against mill sheet or test
certificates shall be used for construction. Check testing shall be carried
out in the absence of MTC. All plates above 40mm shall be 100%
Ultrasonically tested.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
iv) Edge for shop and field weld shall be examined by MPI for plate
thickness >= 32mm.
9.1.3.1 Crushers
The details of the checks to be carried out for various components are to be
submitted by the Contractor for Owner's approval. However, some indicative
checks on different items are given below which should necessarily form part
of the Quality Assurance Plan to be agreed with the Owner.
ii) Shaft forgings and suspension bars to be checked for ultrasonic testing
in addition to check for chemical, mechanical, hardness, microstructure
etc. as per applicable material specification.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 9 (Quality Assurance Plan)
v) No-load trial run test to be carried out at shop to check for speed(RPM),
temperature rise, noise level and vibration.
9.1.3.3.1 Idlers
i) Check for run out and free movement shall be carried out on idlers. Run
out shall be restricted as per IS:8598
ii) Test for dust proofness, water proofness and dynamic friction factor of
the Idlers shall be conducted at shop. The detailed procedures for the
same shall be submitted for review and approval.
9.1.3.3.2 Belting
i) Rubber cover of finished belt shall be checked for tensile strength and
elongation at break before and after ageing. Rubber cover shall also be
checked for abrasion, tear strength and hardness.
ii) For finished belts, checks for elongation at 10% nominal tensile strength
tensile and elongation at break in longitudinal (warp) direction and
tensile in transverse (weft) direction shall be carried out.
iii) Adhesion test between ply to ply and cover to ply shall be carried out.
iv) Troughability test and Test for fire resistance shall be carried out.
v) Test for procedure qualification for belt vulcanizing joint (at site) shall be
done. Procedure for belt vulcanizing joint shall be discussed and finalized
during FQP finalization.
vi) There will be a limitation on the no. of repairs allowed on the belts.
Following will be the acceptance norm for the cover repairs.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 9 (Quality Assurance Plan)
c) The maximum number of patch repair shall not exceed 5 per 100
meter. However, the total number of patch and dough filling repairs
shall not exceed 10 per 100 meters.
vii) In addition to above, Steel Cord belt shall be tested for following also:
b) Finished belt shall be tested for cord pull-out strength before and after
aeging, peeling resistance.
viii) In no case shall the cover thickness or the width of belt be less than that
given in specification.
ix) For testing purpose, belt sample shall be taken from anywhere of the belt
roll length offered
ii) Complete assembly shall be tested at shop for temp. and pressure
developed.
9.1.3.3.4 Pulleys
ii) 100% MPI/DPT on all welds shall be conducted and RT/UT on butt welds
shall be conducted.
iii) Static balancing of pulleys shall be carried out after rubber lagging.
iv) Checks on rubber lagging to include abrasion loss, shore hardness test,
peel-off strength test and physical properties. Peel-off strength shall be
10 kg/cm, Abrasion loss shall be less than 250 cubic mm when tested as
per DIN 53516.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Section- 9 (Quality Assurance Plan)
9.1.3.3.6 Zero speed switch, under belt switch and chute blockage switch
i) Burn in test at 50 deg C for 48 hours shall be done for electronic switches.
iii) HV & IR
(c) Gear reducer shall be checked for reduction ratio, backlash and
contact pattern. No load shop trial run to be conducted on gear boxes
to check for oil leakage, temperature rise, noise level and vibration.
(a) Ultrasonic testing shall be conducted on forgings for gear sleeve and
gear hub, if gear coupling is provided.
(b) MPI shall be carried out after machining to ensure freedom from
cracks.
(b) Check for leak tightness of the coupling shall be carried out.
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
(c) Functional test on fusible plug for each type of coupling shall be
conducted at shop.
ii) Belt scale shall be calibrated with test weight/test chain in static at
works and with test weight for dynamic condition at site.
The tests etc. shall be carried out various components of dust extraction
system offered by the bidder in line with standard industry practice. The details
of the checks to be carried out on the various equipment are to be submitted
by the Contractor for Purchaser’s approval.
iii) Machined and hard faced surface of casting/forging and other hardened,
stellited parts shall be subjected to DPT/MPI in addition to check for case
358
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
vi) No load trial run test shall be carried out at shop on completely assembled
Bucket Elevator to check for trouble free operation, temperature rise, Noise
& vibration. The procedure for the No load trial run shall be submitted for
approval.
ii) Bag Filters: Bag Leakage test shall be carried out for pressure parts.
Pulsing and sequential test on bag filter shall be done.
iii) Butt welds in the tube/separator/body casing of the mill shall be tested by
RT and MP'. All other welds in main tube/separator shall be tested by
MPI/LPI for acceptance. The tube shall be statically balanced.
iv) All gearboxes shall be run tested for adequate duration to check rise in
oil temperature, noise level and vibration. Check for leak tightness of gear
case also shall be performed.
359
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
iii) All major items like plates for casing, head pulley, tail pulley, pulley shaft
and major castings shall be procured with respective material test
certificates.
iv) Calibration check shall be carried out on all feeders.
9.1.3.7.2 Lubricating oil systems
Complete lub oil system shall be checked suitably as per standard practice.
9.1.8 Vacuum Belt Filter System
i) Impeller, casing and shaft of vacuum pumps shall be tested for chemical
and mechanical properties as per relevant standard. All plates above
40mm shall be 100% Ultrasonically tested.
ii) UT on shaft (if greater or equal to 40mm) and impeller shall be carried
out.
iii) All vacuum pumps shall be tested at shop for capacity, power, pressure,
efficiency, noise and vibration etc.
iv) Filter cloths and belts shall be tested for physical properties as per
relevant standard
9.1.9.1 Hooks
i) All tests including proof load test as per relevant IS shall be carried out.
ii) MPE or DPT shall be done after proof load test.
9.1.9.2 Steels castings
Steel castings shall be subjected to DPT on machined surface.
9.1.9.3 Forgings
i) All forgings (wheel, gears, pinions, axles, hooks and hook trunion) greater
than or equal to 50mm diameter or thickness shall be subjected to
ultrasonic testing.
ii) DPT or MPE shall be done after hard facing and machining.
9.1.9.4 Wire rope
Wire rope shall be tested as per relevant standard.
9.1.9.5 Electric hoists
All electric hoists shall be tested as per IS-3938 and chain pulley blocks shall
be tested as per IS-3832.
360
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
e) All centrifugal fans shall be subjected to run test for 4 hour or till
temperature stabilization is reached. Vibration, noise level,
temperature rise and current drawn shall be measured during the run
test.
f) One fan of each type and size will be performance tested as per
corresponding IS code for airflow, static pressure, total pressure,
speed, efficiency, power consumption, noise, vibration and
temperature rise.
ii) PAC shall be subjected to production routine test in accordance with IS:
8148 for the following.
a) General running test.
b) Pressure or leakage test of refrigerant.
c) Insulation resistance test.
d) High voltage test.
e) Performance test on one PAC of each type/size at ambient condition
to check for following:
DBT and WBT of supply and return air.
Air flow
Current, voltage measurement and power consumption
Noise and vibration measurement
iii) Manufacturer’s standard test certificate or guarantee certificate shall be
submitted for split and window air conditioners.
361
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
9.1.12 Elevators
i) The details of the checks to be carried out in the various equipment are
to be submitted by the contractor for owner's approval. However, some
indicative checks on different items are given below which should
necessarily form part of the quality assurance plan to be agreed with the
owner.
ii) All forgings shall be subjected to ultrasonic test to ensure free from
internal defects in addition to check for chemical and mechanical
properties.
v) Gear Reducer shall be checked for gear ratio, backlash, contact pattern.
No load shop trial run shall be conducted on gear boxes to check for oil
leakage, temperature rise, noise and vibration.
viii) Car sling and car body in assembled condition shall be checked for
position of all major components i.e. car sling, inside depth, width, height,
positions of push box, indicator box lights, fans etc.
a) Hydrant Valve:
All valves shall be hydro tested for body and seat.
Capacity test / flow test shall be done as per relevant standard.
362
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
iii) Detectors
b) Piping Protection:
Thickness, Holiday by spark test, Adhesion test shall be carried
out as per relevant standard.
Complete piping shall be Hydro pressure tested, at 1.5 X DP or 2
X MWP whichever is higher, before protection.
c) Welding of Pipes:
ERW Black / rolled welded:
- 100% DPT on root of butt and finish weld of butt and fillet.
- RT on 10% randomly selected joints shall be carried out (for
underground piping).
363
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Gl Pipes
Welding on Gl Pipes in general shall not be done. Welding of Gl
Pipes, if permitted by design, (butt / socket / fillet weld) shall be
done strictly as per approved drawing and procedure approved by
NTPC Engineering. For all such welds 100% DP test and random
1% RT shall be done.
a) 100% DPT on root run of butt weld, nozzle welds and finished fillet
welds.
b) 10% DPT on all finished butt welds.
c) 10% RT (covering all 'T'/cross joints) of butt welds.
ii) Butt welds of dished ends shall be stress relieved and subjected to 100% RT.
iii) Each finished vessels shall be hydraulically tested to 150% of the design
pressure for a duration of 30 minutes.
9.1.14.2 Tanks
i) Tests shall be carried out on the materials of the tanks to establish their
mechanical properties, and chemical compositions
ii) Plates shall be subject to 100% ultrasonic testing.
iii) Welding
a) Root run of butt welds shall be examined by 100% DPT or MPE.
b) Butt welds, full penetration joints and nozzle welds shall be checked
by 100% RT and 100% MPE or DPT.
iv) Rubber lining shall be subject to hardness and spark test, as applicable.
vi) The fabricated tank shall be subject to water fill test to check for the
leakage.
364
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
ii) Dye penetration test of welds of pipes and fittings (including welds of
rolled and welded pipes) shall be carried out.
iii) All pipes and fittings shall be tested as per applicable codes/ standards
at manufacturer’s works.
9.1.15.2 Valves
iii) Machined surfaces of casing, disc and shaft shall be subjected to 100%
MPI or DPT as applicable.
iv) All valves shall be hydraulically tested for body, seat and back seat
(wherever provided) at 1.5 times the maximum pressure to which
respective valves can be subjected during plant operation. Check valves
shall also be tested for leak tightness test at 25% of the specified seat
test pressure. For rubber lined valves, hydraulic test shall be carried out
before rubber lining.
v) For butterfly valves, hydraulic test, seat and disc string test and proof of
design test (if not carried out earlier) shall be carried out in accordance
with latest edition of AWWA-C-504 standard.
vi) Visual and dimensional check shall be carried out for all valves as per
relevant code/ approved drawing.
vii) Functional/ operational checks for and check for smooth opening and
closing of the valves shall be carried out.
365
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
a) Seat leakage test for actuator operated valves, shall be done with
by closing the valves with actuator.
a. Dry cycle test (spring cycle test) for one lakh cycles shall be carried
out as a type test.
366
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
i) For rubber lining, the following tests shall be carried out as per IS-4682
part-I or acceptable equivalent standard:
a) Adhesion test
b) Measurement of thickness
c) Shore hardness test
d) Visual examination and spark test at 5 kV/mm of thickness
e) Bleeding resistance test (as applicable) with keeping the sample in
33% HCl, 48% NaOH and DM water for 72 hours.
f) Bleeding test and ozone resistance test shall be done on rubber
material.
ii) Dimensional check shall be carried out as per relevant code/ approved
drawing.
Spark test, adhesion test and material test for primer and enameled and coal
tar tapes, as applicable, shall be carried out as per AWWA-C-203-91.
i) Rubber compound test slab after valcanising shall be tested for tensile
strength, elongation and shore hardness. Tests on rubber compound
shall also include hydro stability test as per ASTM D-3137 and ozone
resistance test as per ASTM D- 380.
ii) Fabric strength of synthetic fibre for reinforcement shall be checked, and
test for rubber to fabric adhesion as per IS: 3400 or ASTM D- 413, rubber
to metal adhesion as per IS 3100 or ASTM D-429 shall be carried out.
iii) All expansion joints in assembled condition shall be subjected to vacuum
test at 730 mm Hg under conditions to ensure its suitability to withstand
deflection in each axial transverse and longitudinal direction. Duration of
test shall be of minimum 10 minutes.
iv) All bare bellows shall be subjected to hydraulic pressure test in normal
condition at twice the design pressure for a duration of 30 minutes.
Additionally, all bare bellows shall be subjected to deflection tests under
pressure, pressure being raised from zero to the design value in regular
steps and deflection measured at each step.
v) All expansion joints in assembled condition along with control rod
assembly shall be subjected to deflection test under design pressure.
367
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
vi) Either during the hydraulic test or during the vacuum test, change in
circumference at the top position of the arch shall not exceed 1.5% of
measured circumference at normal position.
vii) Twenty four (24) hours after the above tests, the permanent set (variation
in dimensions with respect to its original dimension) shall be measured
and recorded. The permanent set shall not be more than 0.5%.
viii) Life cycle test and burst test shall be carried out on bellows of each
type, design and size.
368
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
9.1.15.9 Blowers
iii) Ultrasonic testing shall be carried out on all forgings and rotor for dia
50mm and above. MPI/DPT shall be done on machined area of the
components.
iv) During assembly all clearances and alignments shall also be checked
and recorded
369
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
vii) Vibration and Noise level measurement shall be done during shop
performance test.
i) All raw materials used shall have co-related mill test certificate meeting
mandatory checks of material specification.
ii) Completed springs shall be tested for sagging test and load versus
deflection test. For diameter more than 25mm, MPE shall also be carried
out.
iii) Butt welds of thickness 32mm and above shall be tested for UT, and for
butt welds of thickness less than 32mm MPE shall be done. Fillet welds
shall be tested for MPE.
iii) Dampers with viscous fluids shall be checked for viscosity of liquid used,
damping resistance of the damper, stiffness of the damper etc.
iv) Turn-buckle, pipe clamps and hangers of thickness greater than 25mm
shall be checked by MPE or DPT on bent portions.
v) One hanger of each type and size shall be checked for variation in
deflection and travel versus load test.
370
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
NDT, DP or MPI, RT
physical inspection
WPS and PQR
Enclosure/ cubicle Y Y Y Y Y Y
Busbar flexible connector
Y Y Y
and disconnect or link
Steel structure and plate
Y Y
IS:2062
Bushing, post and support
Y Y Y Y Y
insulator (IS:9431 and 2544)
Welding of enclosure and
Y Y Y
conductor
Gasket, silicagel breather Y Y
Complete busduct IS:8084 Y Y Y Y
Y =Test applicable
Site tests :
The following minimum tests/ checks shall be conducted at site. Any other tests/
checks as per the manufacturer’s recommendation shall also be carried out
371
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Model,
Core Loss (on first Job) Hot
Chemical Composition
Mechanical properties
NDT, DP or MPI, UT
Compatibility with oil
Rating,
Thermal properties
Magnetic
Electrical strength
Items/ Components/
Routine Tests
Make, Type,
Ageing Test
Polarity,
checks
Spot
and
test
TC,
Tank, HV and LV Cable
Y Y Y Y
Box/ Flange throat
Conservator/ Radiator/
Y Y Y
Cooler/ Pipes
Copper Conductor
Y Y Y Y
(IS:191)
Insulating Material Y Y Y Y Y Y
CRGO Lamination and
Y Y Y Y Y Y
Built Core
Bushing / Insulator
Y Y Y Y
( IS:2544/ 5621)
Gasket Y Y Y Y
Transformer oil (
Y
IS:335)
Off-circuit tap changer Y Y
Core coil assembly and
Y Y
pre-tanking
Marshalling box Y Y Y
WTI, OTI, MOG, PRD,
Breather, Terminal
Connector, Bucholz Y Y
Relay, Globe and Gate
Valve,
Welding (ASME Sect-
Y Y
IX)
Complete Transformer
Y Y
(IS:2026)
Y =Test applicable
372
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Chemical properties
Thermal properties
Electrical strength
systems
NDT, DP or MPI
Routine tests
polarity
Enclosure door, HV and LV
Y Y Y
Cable box/ Flange throat
Copper conductor Y Y Y Y
Insulating material Y Y Y
CRGO lamination and built
Y Y
core
Bushing/ Insulator ( IS:2544/
Y Y Y
5621)
Gasket Y Y Y
Off-circuit tap changer Y Y
Core coil assembly Y Y
Marshalling box Y
WTI, Thermister, Terminal
Y Y
connector
Welding Y
Complete transformer
Y Y Y
(IS:11171)
Y =Test applicable
Site tests :
The following minimum tests/ checks shall be conducted at site. Any other tests/
checks as per the manufacturer’s recommendation shall also be carried out
a) Dry out test
b) Resistance measurement of windings
c) Ratio test
d) Vector group test
e) Tap changer test
f) Buchholz relay test
g) Low oil level alarm.
h) Temperature indicators
i) Marshalling kiosk
j) Protective relays
k) Magnetizing current
373
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
9.2.3 Motors
Tests/ Checks
Electrical characteristics
Magnetic characteristics
Sub-system
Thermal characteristics
NDT, DP or MPI, UT
Dynamic balancing
Heat treatment
Metallography
Dimensional
Over speed
inspection
index test
Vibration
Run out
Visual
374
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Stator, Rotor,
Terminal Box Y Y Y
assembly
Accessories, RTD,
BTD,CT, Brushes,
Diodes, space
heater, antifriction Y Y Y
bearing, cable
glands, lugs,
gaskets etc.
Complete motor
Y
(IS: 325/ IS:4722/ Y Y Y Y Y Y
1
IS:9283)
Y =Test applicable, Y1 = for 11kV and 3.3kV motors only
Note
This is an indicative list of tests/ checks. The manufacture is to furnish the
detailed Quality Plan indicating the practices and procedure followed along with
relevant supporting documents during QP finalization. However QP approval is
not envisaged for 415V motors upto 50 KW.
Site Tests :
The following minimum tests/ checks shall be conducted at site. Any other tests/
checks as per the manufacturer’s recommendation shall also be carried out
i) Measurement of vibration.
ii) Measurement of insulation resistance and polarization index
iii) Measurement of full load current.
iv) Test running of the motors, checking the temperature rise and identifying
the hot spot etc.
375
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Functional Checks
HV and IR Test
Items/ Components/ Sub-
systems
376
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Functional checks
HV and IR Test
Items/ Components,/ Sub-
system
finish
Diodes Y Y Y Y Y
Terminal Blocks Y Y Y Y
Synthetic Rubber Gasket
Y Y Y Y
( IS:11149/ 3400 )
Breaker Handling Trolley Y Y Y Y Y
HT Switchgear Panel
Y Y Y Y Y Y Y Y Y Y Y
(IS:3427)
Y =Test applicable
Site tests: The following minimum tests/ checks shall be conducted at site. Any
other tests/ checks as per the manufacturer’s recommendation shall also be carried
out.
a) General
i) HV test on complete switchboard with CT and breaker/ contactor in position
ii) Check continuity and IR value of space heater
iii) Check earth continuity for the complete switchgear board
b) Circuit Breaker/ Contactors
i) Check control wiring for correctness of connections, continuity & IR values
ii) IR values, resistance and minimum pick up voltage of coils
iii) All functional checks and electrical & mechanical interlocks provided
iv) Checks on spring charging motor, correct operation of limit switches and
time of charging
c) Current and Voltage Transformers
i) Insulation resistance test
ii) Ratio test on all cores
iii) Polarity test
d) Relays
i) Insulation resistance between AC to DC terminals and between all
terminals and body
ii) Check minimum pick up voltage of DC coils
iii) Relay settings
377
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Mechanical properties
Chemical properties
Electrical properties
IR – HV – IR Test
Sheet steel (IS:513) Y Y Y Y Y
Aluminum bus bar material
Y Y Y Y Y Y
(IS:5082)
Copper bus bar material
Y Y Y Y Y Y
(IS:613)
Support insulator
Y Y Y Y Y
(IS:943, IS:10912, IEC: 660 )
Air circuit breaker
Y Y Y Y Y Y Y
(IS:13947)
Energy meters ( IS:722 ) Y Y Y Y Y Y
Power and auxiliary contactor
Y Y Y Y Y
(IS:13947)
Protection and auxiliary
Y Y Y Y Y Y
relays (IS:3231)
Control and selector switches
Y Y Y Y Y
(IS:6875)
CT and VT (IS 2705/ 3156) Y Y Y Y
MCCB ( IS:13947 ) Y Y Y Y
Indicating meters (IS:1248) Y Y Y Y Y Y
Indicating lamps (IS:13947) Y Y Y Y Y
Air break switches ( IS:13947
Y Y Y Y Y
)
Control terminal blocks Y Y Y Y
Y =Test applicable
378
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
IR – HV – IR Test
standards and
specification
Finish
Fuse (IS:13703) Y Y Y Y Y
Control
transformer Y Y Y Y Y Y
(IS:12021)
Push Buttons
Y Y Y Y Y
(IS:4794)
Transducer
Y Y Y Y Y Y
(IEC:60688)
MCB (IS:8828) Y Y Y Y Y
Breaker
Y Y Y Y Y Y
handling trolley
Synthetic rubber
gasket Y Y Y Y Y
(IS:11149)
415V
Switchgear Y Y Y Y Y Y Y Y Y Y Y
(IS:8623 )
Y =Test applicable
379
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Items/
Electrical clearances
Chemical properties
Electrical properties
IR – HV – IR test
finish
(TC)
Aluminum sheets/
plates/ strips /
Y Y Y Y Y Y Y
flexibles/ tubes
(IS:5082/ 737)
CRCA flats/ ISMC
Y Y Y Y Y
(IS:2062)
Neoprene/
synthetic rubber
Y Y Y Y
gaskets (IS:11149/
3400)
Rubber bellows
Y Y Y Y
(IS:3400)
Support insulator
(BS:2782, IEC:660, Y Y Y Y
IS:10912 )
Galvanized
structure and GI
earthing flat Y Y Y Y
(IS:2629/ 2633/
4749)
Space heater and
Y Y
Thermostat
LT busduct
Y Y Y Y Y Y Y Y Y Y Y
(IS:8623 Part 2)
Y = Test applicable
380
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Site tests :
The following minimum tests/ checks shall be conducted at site. Any other tests/
checks as per the manufacturer’s recommendation shall also be carried out.
a) General
i) HV test on complete switchboard with CT and breaker/ contactor in position
ii) Check continuity and IR value of space heater
iii) Check earth continuity for the complete switchgear board
d) Relays
i) Insulation resistance between AC to DC terminals and between all
terminals and body
ii) Check minimum pick up voltage of DC coils
iii) Relay settings
e) Bus duct
i) Power frequency voltage withstand test
ii) Insulation resistant measurement of equipment and all wiring
iii) Milli-volt drop test
381
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Mechanical properties
Chemical composition
length
Aluminium (IS-8130) Y Y Y Y Y
Semi conducting
Y Y Y Y
compound
XLPE compound
Y Y Y Y Y
(IS-7098- Part-II)
FRLS PVC compound
(IS-5831, ASTM-D2843,
Y Y Y Y
ASTM-2863, IEC-754
Part-1)
Triple extrusion and
curing/ Manufacturing of Y Y Y Y
core
Copper tape Y Y Y Y
Polyster tape Y Y
Armour wire/strip Y Y Y
Copper tapping Y Y Y
Inner sheath Y Y
Armouring Y Y
Outer sheathing Y Y Y Y
Power cable (Finished)
(IS : 7098 Part-II)
IEC:332, IS-5831, Y Y Y Y Y Y
ASTM-D2843, ASTM-
2863,IEC-754 Part-1)
Wooden
drum(IS:10418)/ Y
Steel drum
Y =Test applicable
382
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
as per specification
specification
tests
feature
drums
FRLS
per
Aluminium (IS-8130)
Semi conducting compound
XLPE compound (IS-7098- Part-II)
FRLS PVC compound (IS-5831, ASTM-D2843, ASTM-
Y
2863, IEC-754 Part-1)
Triple extrusion and curing/ Manufacturing of core
Copper tape
Polyster tape
Armour wire/strip
Copper tapping
Inner sheath
Armouring
Outer sheathing Y Y
Power cable (Finished) (IS : 7098 Part-II) IEC: 332, IS-
Y Y Y
5831, ASTM-D2843, ASTM-2863,IEC-754 Part-1)
Wooden drum(IS-10418) /Steel Drum Y
Y =Test applicable
Notes
1) Additional acceptance tests like FRLS, thermal stability, tensile strength and
elongation after ageing shall be done on one sample/ lot
2) Length measurement/ surface finish/ eccentricity/ ovality shall be checked on
one length/ size/ lot
3) Routine test shall be carried out on each drum length as per specifications.
383
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Mechanical properties
Chemical composition
Spark test
sheath *
sheath
length
Aluminum (IS-8130) Y Y Y Y Y
PVC compound (IS-5831) Y Y Y Y
XLPE compound (IS-7098
Y Y Y Y Y
Pt-I)
FRLS PVC compound (IS-
5831 ) ASTM-D-2843/
Y Y Y
ASTM-D-2863 IEC-754
Part-I
Armour wire/strip (IS-3975) Y Y Y
Insulated core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y
Finish cable (IS-1554 and
7098 – Part-1) ASTM-D-
2843/ ASTM- D-2863 IEC-
754 Part-I Swedish Y Y Y Y Y Y
Chimney SS 4241475 for
(F3 category) Flammability
test IEC-332 Part –3 Cat-B
Wooden drum (IS-10418) /
Y
Steel drum
Y =Test applicable
384
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
specification
FRLS Tests
drums
Aluminum (IS-8130)
PVC Compound (IS-5831)
XLPE Compound (IS-7098 Pt-I)
FRLS PVC Compound (IS-5831 ) ASTM-D-
Y
2843/ ASTM-D-2863 IEC-754 Part-I
Armour wire/strip (IS-3975)
Insulated Core
Laid up core
PVC Inner sheath
Armouring
Outer sheath Y
Finish cable (IS-1554 & 7098 – Part-1) ASTM-
D-2843/ ASTM- D-2863 IEC-754 Part-I Swedish
Y Y Y
Chimney SS 4241475 for (F3 category)
Flammability test IEC-332 Part –3 Cat-B
Wooden drum (IS-10418) / Steel drum Y
Y =Test applicable
Notes
1) (*) Not applicable for XLPE insulation
2) Additional acceptance tests like FRLS, thermal stability, tensile
strength and elongation after ageing shall be done on one sample /
lot.
3) Length measurement / surface finish shall be checked on one length/
size/ lot
4) Routine test shall be carried out on each drum length as per
specifications.
385
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Mechanical properties
Chemical composition
Electrical properties
Spark test
sheath
length
Copper conductor (IS-8130) Y Y Y Y Y
PVC compound (IS-5831) Y Y Y Y
FRLS PVC compound IS-
5831 ASTM-D-2843/
Y Y Y
ASTM-D-2863 IEC-754
Part-1
Armour wire/strip (IS-3975) Y Y Y
Insulated core Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y
Finished cable (IS-1554)
ASTM-D-2843/ ASTM-D-
2863 IEC-754 Part-1
Swedish Chimney: SEN SS Y Y Y Y Y Y
424-1475( F3 category)
Flammability test IEC-332
Part-3 Cat-B
Wooden drum( IS:10418)/
Y
Steel drum
Y =Test applicable
386
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
specification
specification
FRLS test
drums
Copper conductor (IS-8130)
PVC compound (IS-5831)
FRLS PVC compound IS-5831 ASTM-D-2843/
Y
ASTM-D-2863 IEC-754 Part-1
Armour wire/strip (IS-3975)
Insulated core
Laid up core
PVC Inner sheath
Armouring
Outer sheath Y
Finished cable (IS-1554) ASTM-D-2843/ ASTM-D-
2863 IEC-754 Part-1 Swedish Chimney: SEN SS
Y Y Y
424-1475 ( F3 category) Flammability test IEC-
332 Part-3 Cat-B
Wooden drum( IS : 10418) / Steel drum Y
Y =Test applicable
Notes
1) Additional acceptance tests like FRLS, thermal stability, tensile
strength and elongation after ageing shall be done on one
sample/ lot
2) Length measurement / surface finish shall be checked on one
length/ size/ lot
3) Routine test shall be carried out on each drum length as per
specifications.
387
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Galvanize test
Deflection test
IP protection
specification
Items/ Components/ Sub-
Dimension
HV and IR
Proof load
systems
388
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Site tests :
The following minimum tests/ checks shall be conducted at site. Any other tests/
checks as per the manufacturer’s recommendation shall also be carried out
i) Cables
a) Check for physical damage
b) Check for insulation resistance before and after termination/
jointing.
c) HT cables shall be pressure tested (test voltage as per IS:7098)
before commissioning
d) Check of continuity of all cores of the cables.
e) Check for correctness of all connections as per relevant wiring
diagrams. Any minor modification to the panel wiring like
removing/ inserting, shorting, change in terminal connections, etc.
shall be carried out
f) Check for correct polarity and phasing of cable connections
g) Check for proper earth connections for cable glands, cable boxes,
cable armour, screens, etc.
h) Check for provision of correct cable tags, core ferrules, tightness
of connections
389
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Sub-system
Insulation Resistance
(Acceptance test)
and finish
adhesion
390
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Manufacturer’s standards
Resistance to alkali
Impact strength
391
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
test)
test)
Container and Lids ( IS:1146)
Vent Plugs
Perforated steel strips
Active material for positive and
negative Plates
Separators
Electrolyte
Inter-cell connectors and
fasteners
Battery stand
Cell Insulators
Stack assembly Y Y
Ni-Cd Battery (IS:10918 ) Y Y Y Y
Y =Test applicable
Site tests :
The following minimum tests/ checks shall be conducted at site. Any other tests/
checks as per the manufacturer’s recommendation shall also be carried out.
i) Physical examination
ii) Dimensions, mass and layout
iii) Marking
iv) Polarity and absence of short circuit.
v) Insulation resistance
vi) Ampere - hour capacity
vii) Retention of charge
viii) Air pressure test
392
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
checks
Item/ Components/ Sub-system
HV and IR test
constructional
specification
thickness,
adhesion
process
393
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Site tests :
The following minimum tests/ checks shall be conducted at site. Any other tests/
checks as per the manufacturer’s recommendation shall also be carried out
i) Complete physical examination
ii) Checking of proper operation of annunciation system
ii) Temperature rise test at full load
iv) Insulation resistance test
v) Automatic voltage regulator operation
vi) Load limiter operation
vii) Dynamic response test
394
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
9.2.10.1 DC Reactor
ATTRIBUTES/
CHARACTERISTICS
Welding/ NDT
ITEMS/ COMPONENTS, Dimensional
Visual
SUB_SYSTEM ASSEMBLY
395
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Chemical composition
Routine test
Ageing Test
Items/Components
Sub Systems
396
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
397
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Physical Inspection
Electrical Strength
Routine test
Items/Components
Sub Systems
398
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Dimension/ Finish
Item/ Components/
HV/ IR
Sub-system/ Assembly
Aluminum / Copper Y Y Y Y
Busbar (IS-5082/IS-
613/IS-1987)
Support Insulator (BS- Y Y Y Y
2782/IEC-660/IS-10912)
Control / Selector Y Y Y
Switch(IS6875)
Contactor/ MCB (IS- Y Y Y
13947)
O/L Protection relays(IS- Y Y
3231)
C.T /V.T/ Indicating Y Y Y
Meter(IS2705/3156/1248)
Fuse/ Fuse carrier (IS- Y Y Y
13703)
Terminals/lugs/PVC Y Y Y Y Y
wires(IS13947//IS-694)
Timers (IS-3231) Y Y Y
Push Button/ Lamp/ (IS- Y Y Y
6875)
Control Transformer Y Y Y
(IS12021)
Mimic, Annunciator Y Y
GASKET(IS-11149) Y Y Y Y Y
Fabrication Y
Pretreatment & Painting Y Y
VFD panel Y Y Y Y Y
399
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
NOTE:
400
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Pre-treatment of sheet
Galvanization Tests
standard
HV & IR
IP Test
Items/Components
Finish
spec.
Sub Systems
Luminaries (IS:10322
Pt.5 Sec.1 (Non-LED Y Y Y Y Y Y
type)
Electronic Ballast Y Y Y Y
Lighting wire (IS:694) Y Y
Fans (IS:374) Y Y
Pole (IS:2713) Y Y Y Y Y
Lamps (IS:9800,
Y Y Y
IS:9974)
Lighting Mast (with
raise & lower lantern Y Y Y Y Y Y
type)
Wall mounted Lighting
Y Y Y Y Y Y Y Y Y Y Y Y
Panel (IS:513, IS:5)
Switch Box/ Junction
Box/ Receptacles/ Local
Push Button Station/ Y Y Y Y Y Y Y Y Y Y Y Y
Lighting Panel (IS:513,
2629, 2633, 4759,6745)
Cable Gland (BS:6121) Y Y Y
Cable lug (IS:8309) Y Y Y
Flexible Conduit Y Y
Lighting Transformer
Y Y Y
(IS:11171)
Epoxy & Galvanised
Conduit (IS:9537, 2629, Y Y Y Y
2633, 4759, 6745)
401
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
TESTS
402
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
TESTS
** if applicable
403
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
IR & HV (R)
Tubing (R)
Wiring (R)
Visual (R)
Standard
ITEMS
Local Instrument Y Y Y Y Y Y Y Y Y Y Y Y Y
enclosure
Local instruments Y Y Y Y Y Y Y Y Y Y Y Y Y
racks
Junction Box Y Y Y Y Y Y Y
*
Gauge Board Y Y Y Y Y Y Y Y Y
Impulse pipes and Y Y Y Y Y
tubes
Socket weld fittings Y Y Y Y Y
ANSI B-
16.11
Compression fittings Y Y Y Y Y Y
Instrument valves & Y Y Y Y Y
Valve manifolds
Copper tubings Y Y Y
ASTM B75
* applicable for painted junction boxes.
R-Routine Test A- Acceptance Test Y – Test
applicable
404
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
++
Instrument cable twisted and
shielded
Conductor(IS-8130) Y Y Y
Insulation(VDE-207) Y Y Y Y Y Y
Pairing/Twisting Y Y Y
Shielding Y Y Y
Drain wire Y Y Y Y Y
Inner Sheath Y Y Y Y Y Y
Outer Sheath Y Y Y Y Y Y
Over all cable Y Y Y Y Y Y Y Y Y
Cable Drums(IS-10418) Y Y
(R) - Routine Test (A) - Acceptance Test (Y) - Test Applicable
405
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Note :
1. High Temp. cables shall be subjected to tests as per VDE-207 (Part-6)
Compensating cables shall be checked for Thermal EMF/ Endurance test as per IS
8784.
2. This is an indicative list of tests/checks. The manufacture is to furnish a detailed
Quality Plan indicating his practice & Procedure along with relevant supporting
documents during QP finalization for all items.
3. Sampling Plan for Acceptance test shall be as per IS 8784 (As applicable)
* FRLS Tests: Oxygen/ Temp Index (ASTM D-2863), Smoke Density Rating
(ASTM–D 2843), HCL Emission ( IEC-754-1)
** Characteristic Impedance, Attenuation, Mutual Capacitance, Cross Talk (As
applicable)
+ Sample size will be One No. of each size/ type per lot.
++ Sample size will be One No. sample for complete lot offered irrespective of size/ type
9.3.4 Control Desk, PLC Panel, Smoke Detector, Fire Alarm & Control
System
TESTS
Review of TCs for instruments/ devices/ Recorders,
indicators/ osaic items/ Transducers (R)
Illumination (R)
Dimension (R)
IR & HV (R)
Wiring (R)
Visual (R)
Mimic (R)
ITEMS
1. Control Desk Y Y Y Y Y Y Y Y Y Y Y Y Y
2. Annunciation/ Control/ Y Y Y Y Y Y Y Y Y Y Y Y
PLC Panel
406
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
3.Smoke Detectors Y
(UL-268,EN-54 PT-7), Heat
Detectors( UL-521/ EN54
PT-5 ) Annunciation/
Control
Panel (UL -864, EN-54, PT-
2)
* Applicable for PLC
407
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
TESTS
IR/ HV (R)
ITEMS
UPS/CONVERTER
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
(IEC-146 PT-4)
VOLTAGE STABILISER Y Y Y Y Y Y Y Y
LEAD ACID BATTERY
Y
(TUBLER) IS:1651
LEAD ACID BATTERY
Y
(PLANTE) IS:1652
NICKEL-CADMIUM
Y
BATTERY (IEC-623)
* Transfer time and Over shoot /under shoot during load & system transfer shall be
recorded
Note:
This is an indicative list of tests/checks. The manufacturer is to furnish a
detailed quality plan indicating the Practices and Procedure adopted alongwith
relevant supporting documents.
408
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
accessories (R)
Dimension (R)
Mpi/ dp (R)
ITEMS
CONTROL VALVE
AND ACTUATOR
Overall Y Y Y Y Y Y Y Y Y
Body Y Y Y Y Y Y Y
Bonnet Y Y Y Y
Trim Y Y Y*
Pneumatic actuator Y Y Y
Electro pneumatic Y Y
positioner
Y* - UT ON SPINDLE DIA ≥ 40 MM.
(R) - ROUTINE TEST (A) - ACCEPTANCE TEST (Y) -
TEST APPLICABLE
NOTE :
This is an indicative list of tests/checks. the manufacture is to furnish a detailed
quality plan indicating his practice & procedure along with relevant supporting
documents during QP finalisation for all item.
409
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Test/ Attributes
Safety
check (Single phasing, Phase correction, Tripping etc.) (A)
Characteristics
ASSEMBL
Y/TESTIN
ELECTRICAL
ACTUATOR WITH
INTEGRAL
STARTERS
(IS:9334)
Motor Y Y Y Y Y
Final Testing Y Y Y Y Y Y Y Y Y Y Y Y Y
NOTE :
This is an indicative list of tests/checks. The manufacturer is to furnish a
detailed quality plan indicating the practices & procedure along with relevant
supporting documents.
410
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
9.4.1.1 General
i) This part of the specification covers the sampling, testing and quality
assurance requirement for all civil and structural works including
excavation and filling, cast in situ concrete and allied works,
fabrication and erection of structural steel works, masonry / sheeting
and allied works, finishing items, etc.
ii) The Contractor shall carry out all sampling and testing in accordance
with the relevant Indian standards and / or international standards and
this technical specification. Where no specific testing procedure is
mentioned, the tests shall be carried out as per the best prevalent
engineering practices and to the directions of the Purchaser. The
Contractor shall establish the QA&QC laboratory at site. All sampling
and all field tests shall be done in the presence of the Purchaser or his
authorised representative. The tests which cannot be carried out in the
field laboratory shall be done at a laboratory of repute such as CSMRS,
NCBM, IITs, National Test House, Kolkata etc. as agreed by the
Engineer. The cost of transportation and other associative cost
including the test charges shall be borne by the contractor and be shall
deem to be included in his contract price.
iii) The recommendations and suitability of material for concreting and
other building materials like brick, cement, aggregates etc., shall be
ascertained by contractor prior to start of work. Preliminary evaluation of
aggregate and its evaluation for potential alkali-aggregate reactivity as
per following shall be done:-
A. Evaluation of Aggregates:
411
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
412
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Based on the schedule of work agreed with the Purchaser and the
approved FQP, the Contractor shall prepare a schedule of tests and
submit them to the Purchaser and organise to carry out the tests as
scheduled/ agreed.
viii) The contractor shall prepare and obtain approval of the Owner of the
Field Quality Plan (FQP) well before the start of the work. This FQP
shall cover for all the items / activities covered in the contract/schedule
of items and required for completion of the work.
ix) All materials / components and equipment covered under the scope of
work which are to be manufactured at shop/ factory of the
vendor/subvendor shall be covered under a comprehensive quality
assurance programme. Manufacturing Quality Plan (MQP) shall detail
out all the components and equipment, various test/inspection, to be
carried out as per the requirements of this specification and standards
mentioned therein.
x) All the equipment shall be duly calibrated by NABL/ NPL accredited
laboratories/accreditation agencies.
xi) The Contractor shall submit to the Purchaser Field Welding Schedule
for field welding activities, the format for Field Welding Schedule shall
be furnished to the Contractor at pre-award stage. The field-welding
schedule shall be submitted to the Purchaser along with all supporting
documents, like welding procedures, heat treatment procedures, NDT
procedures etc. at least ninety days before schedule start of erection
work at site. The Contractor shall submit Welding Procedure
Specification (WPS) for Purchaser approval/ acceptance, the format
for the WPS shall be furnished to the Contractor during post bid
discussion stage.
413
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
All welding and brazing shall be carried out as per procedure drawn
and qualified in accordance with requirements of ASME Section IX/BS-
4870 or other International equivalent standard acceptable to the
Purchaser. All welding/brazing procedures shall be submitted to the
Purchaser or its authorized representative for approval prior to carrying
out the welding/brazing.
All brazers, welders and welding operators employed on any part of the
contract either in the Contractor’s/ sub-Contractor’s works or at site or
elsewhere shall be qualified as per AWSD1.1/ASME Section-IX or BS-
4871 or other equivalent International Standards acceptable to the
Purchaser.
Welding procedure qualification and Welder qualification test results
shall be furnished to the Purchaser for approval. However, where
required by the Purchaser, tests shall be conducted in presence of
Purchaser /authorized representative.
414
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
All materials shall be stacked and stored by the Contractor as per IS-4082
and as per the requirements specified in Purchaser Technical Specification.
9.4.2.2 Excavation and filling works
a) When only one set of sample is tested, then all individual samples
collected and tested should pass without any deviation
b) For retest of any sample two additional samples shall be collected
and tested, and both should pass without any deviation.
c) Where a large number of samples are tested for a particular test
then 9 samples out of every 10 consecutive samples tested shall
meet the specification requirement.
415
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
For concreting works provisions of technical specifications and IS: 456 shall
apply. A detailed methodology for concrete works shall be submitted by
the contractor to Purchaser for approval.
The methodology for concrete works shall broadly contain the suitability of
source of aggregates, cement, admixture, water and reinforcement steel,
etc. t he available concrete mix design, results of trial mix carried out at
site, method / control of batching, mixing, transportation, layer wise
placement, compaction, fixing / removal of form work, staging, fixing of water
stops at appropriate locations along with specials, expansion joints,
contraction joints and construction joints, cover blocks and method of
curing, methodology of repair of newly placed hardened concrete, testing
and sampling of concrete during production and placement and acceptance
checks for final clearance.
Exposed surfaces of concrete shall be kept continuously in a damp or wet
condition for at least seven days from the date of placing concrete in case of
ordinary Portland cement, not be less than 10 days for concrete exposed
to dry and hot weather conditions, at least 10 days or period may be
extended to 14 days where mineral admixtures or blended cements are used.
416
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Approved curing compounds may be used in lieu of moist curing with the
permission of purchaser.
vi. Records giving the details of rectification giving the location of grouting,
the quantity of grout used at each location, type of grout used
417
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
xii. Details of curing, staging and fixing / removal of formwork, checklist for
formwork as per IS 14687 including all machine foundations
For structural steel works provisions of technical specifications and IS: 800
shall apply. A detailed methodology for structural steel works shall be
submitted by the contractor to Purchaser for approval.
418
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
No welding shall be carried out on cast iron components for repair. All
the heat treatment results shall be recorded on time temperature charts
and verified with recommended regimes.
Fillet Weld
419
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
4
Macro-etch examination on Minimum one joint per built up
production test coupons for main beams, columns and crane
fillet welds girder etc.
5
Tension member of crane girder Dye penetration test on
25% weld length
6
All other fillet welds DPT on 5% of weld length with
minimum 300mm at each
location
Butt Weld
7
DPT 100% after back gouging on
all butt welds
8
Mechanical testing of production Minimum one joint per built
test coupons up beam, column and crane
9 girder.
Radiography test on butt 100% RT on butt welds of
welds tension flange (bottom flange)
of crane girders
(In case of failure of any welds in
SPOT/RT or UT the % of retesting 10% RT weld length of each
shall be doubled at that particular welder on butt welds,
location. Acceptance criteria of
NDT on welds shall be as per AWS
D1.1.
10 Wherever
Ultrasonic RT is not
testing onfeasible
full UT to 100% UT on the web to
be carried out
penetration with(other
welds the approval
than butt of flange joint of crane girder
the engineer)
welds)
10% UT on other full
penetration joints
11
Control assembly checkin shop 1st and further every 10th set
before erection of identical structure
12
Dimensional tolerances during as per IS-7215 and IS-12843
fabrication and erection
13
Surface Preparation and Paint SA 2 1/2 , By elcometer
thickness random after each coat, each
member
420
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
The contractor shall submit the work methodology which shall include the
type, grade and make of materials along with their technical data sheets,
details, etc., clearance from E-I-C regarding leak proofness and damp
proofness of parent concrete surface, surface preparation, the procedure of
application, curing, testing and acceptance.
The tests shall be carried out on acid resistant bricks / tile- water absorption,
421
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
Fire Proof doors shall be tested for the requirements mentioned in the
Technical Specification. The type test of the doors shall be carried out at
CBRI Roorkee for minimum 2 hours fire rating and its Fabrication drawing
shall also be approved by CBRI, Roorkee. DFT of paint of Fire Proof Doors
and its fittings and fixtures as per BOQ shall be checked. The doors shall be
finished with suitable fire retardant painting system
422
Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
(FGD) System in a Typical 2x500 MW Thermal Power Plant
Section- 9 (Quality Assurance Plan)
b) Muck Debris should be removed from the pile bore by air lift technique
(by keeping the tremie & air pipe as close as to bottom of pile bore)
i.e. after completion of boring, after completion of SPT (wherever
applicable), after lowering reinforcement cage, but before start of
concreting.
c) Density of bentonite slurry shall be checked from the sample taken from
the bottom of pile bore (not at 1.0 m above the bottom of the pile bore)
d) While lowering the R/F cage into the pile bore, two hooks shall always
be used to ensure balanced/symmetrical insertion of cage into the pile
bore.
e) Concrete cover blocks at the junction of two R/F cage shall be
ensured before lowering the second segment.
f) Surge concreting of about 1.0 cum shall be ensured at the start of
concreting (i.e. in the first pour), by suddenly allowing to fall through the
tremie pipe from the funnel. This will help in displacing left out
muck/debris in the pile bore (by the impact).
h) In a pile group, SPT shall be carried out at termination level in the pile,
taken up first.
k) Low strain pile integrity test on all job piles and test piles shall be
conducted as specified in the Technical Specification. This test shall be
suitably used to identify the piles for routine tests. High Strain dynamic
test shall be done as per the technical specification. The frequency of
the test shall be as per the BOQ
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Section- 9 (Quality Assurance Plan)
Pile load testing shall conform to the requirements of IS-2911 (Part IV)
and the technical specification. Initial load tests as specified in the contract
documents shall be conducted to assess the safe load carrying capacity of
pile before start of work. To verify the load carrying capacity of the working
piles, routine load test shall be conducted.
Pile load-testing procedure and the test setup / scheme shall be submitted
for approval of Purchaser.
All the gauges and instruments shall be calibrated before the start of the tests
on test piles and working piles and the calibration record shall be verified
before start of execution of the test.
Material used for sanitary and plumbing fittings and fixtures shall conform to
and be tested as per the requirements of relevant IS Codes specified in
t echnical specification.
The obstructions in sewer lines shall be checked by inserting a smooth
ball, of diameter 13 mm less than the pipe bore at the high end of the
sewer or drain. If absence of any obstructions, such as yarn or mortar
projecting through the joints, ball shall roll down the invert of the pipe and
emerge at the lower end. The straightness shall be checked by means of a
mirror at one end of the line and lamp at the other. If the pipeline is straight,
the full circle of the light may be observed. The mirror will also indicate
obstruction in the barrel, if the pipeline is not straight.
The service pipes shall be slowly and carefully charged with water, allowing
all air to escape avoiding all shock or water hammer. The service pipe shall
then be inspected under test / working condition of pressure and flow, when
all draw-off taps are closed. The service pipes shall be checked for
satisfactory support and protection from damage, corrosion and frost.
Material used for sanitary and plumbing fittings and fixtures, floor finishes
and allied work shall conform and tested as per the requirements of relevant
IS Codes specified in Purchaser technical specification.
Fabricated item like metal doors, windows, ventilators, louvers, rolling
shutters and grills etc. shall be checked for correctness of locations and
smoothness of operation and fixtures. All controls and locking devices shall
give fault free performance. Door and window shutters shall operate without
jamming. The clearance at head and jamb for door shutters shall not exceed
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Section- 9 (Quality Assurance Plan)
1.5 mm. For double leaf doors, the gap at the meeting stiles shall not be
more than 2.5 mm.
Materials used in glass and glazing shall be procured from source
approved by Purchaser and shall conform to the requirements of the
Technical Specification and IS Codes.
False ceiling panels shall be best quality material in thickness and properties
called for in the specification / schedule of items. Material Test Certificate to
be submitted before bulk supply.
All bought items covered in the scope of contract shall be procured from
sources approved by Purchaser and shall conform to the requirements of
the technical specifications and referred standards /codes.
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Annexures
ANNEXURES
Annexure-I
RAW WATER ANALYSIS
7. Carbonate CaC03 0
9. Iron Fe 2.0
OC
12. Temperature 43
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Annexure-II
Cooling Water Analysis
7. Carbonate CaCO3 0
9. Iron Fe 0.75
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Annexures
Annexure-III
Clarified Water Analysis
4. Bicarbonate CaCO3 41 .7
7. Carbonate CaCO3 0
9. Iron 0.30
1 1. Turbidity NTIJ 10
OC
12. Temperature CC) 43
Note: At the outlet of clarifier of PT Plant
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Annexure-IV
DM Water Analysis
2. Iron as Fe Nil
5. Conductivity
Not more than 0.1
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Annexure-V
Limestone Analysis
1. CaO 45.9—51.0
2. MgO 0.9-3.8
3. Fe2O3 0.45-1 .0
4. A12O3 1 .19-2.1
5. Si2O3 2.1-4.5
6. Mn2O3 <0.12
7. P2O5 Traces
8. <0.015
Cl2
9. <0.16
Na2O
10. K2O <0.01
1 1. TiO2 <0.02
12. Total Sulphur <0.1
13. LOI 38.0-41 .3
14. Bond Index 13
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Annexure-VI
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Annexure-VII
Record Notes of Discussion of 1st meeting of the Committee for Review of Draft technical
specification for FGD Plant retrofit as prepared by CEA held on 11.08.2017 at CEA
(Issued by CEA vide email dated 14.08.2017)
At the outset, Chief Engineer (TETD) welcomed all the participants and apprised about the
background and necessity for framing the specification for wet limestone FGD technology. He
apprised that soft copy of preliminary draft prepared by CEA has already been made available
to the committee members. He further apprised about basic scheme and components of wet
limestone FGD system included in the draft specification. The gist of the discussion held in the
meeting regarding review of draft technical specification as prepared by CEA is as below:
1. GE Power enquired whether specifications being draft covers only functional aspects
(basic design) or it’s a detailed specification covering equipment details as well. It was clarified
that a comprehensive technical specification including general technical aspects, scope of work,
guaranteed parameters (including liquidated damages), equipment specification, Quality
Assurance Plan and mandatory Spares etc. The general condition of contract, QR and
commercial aspects etc. shall be covered by the utility.
2. L&T suggested to include transportation of lime stone through railways for larger
capacity plant and its handling/ storage. Further, in case lime stone is available in crushed form,
the option of excluding the lime crushing system may be included in the specification.
3. NTPC raised the issue of whether GGH should be made mandatory for FGD. It was
discussed that GGH has advantage of reducing the temperature of inlet raw flue gas to the
absorber which reduces potential of damage to scrubber internals in case of flue gas excursion
and mal- operation etc. Reheating of treated flue gas helps in increased buoyancy of flue gas
exiting from the chimney resulting in dispersion of pollutants over a wider area and
consequently reduced ground level concentration of pollutants. However, GGH has high cost,
requires additional space, results in additional pressure drop, has leakage issues and other
operational problems. Further, irrespective of whether GGH is provided or not, chimney needs
to be provided with acid resistant lining. As such, it was opined that requirement of GGH may
not be made essential for the FGD system.
4. CEA asked the views of members about partial treatment of flue gas for older plants to
achieve the prescribed emission limits of 600 mg/Nm3. The members from manufacturers’ side
apprised that variation in level of SO2 in the treated flue gas to achieve stipulated MoEF&CC
norms can be achieved by suitably sizing the absorber and also by varying the limestone feed
during operation. Further, operation of bypass damper was indicated to be complex and prone
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to operational issues. The committee members agreed to the view that part scrubbing of the flue
gas and blending with remaining untreated flue gas should be avoided.
5. BHEL suggested to include the option of providing common scrubber for multiple
(smaller) units to save cost and space since many older smaller sized units are having space
scarcity.
6. BHEL/ L&T intimated that only one type of scrubber i.e. multiple spray type has been
covered in the specification and that there are other proven types viz. bubble, fountain (single
spray) etc. available with wet limestone and these need to be covered for more acceptability and
competitiveness. CEA suggested that technical details of FGD scheme indicated in the draft
specification may be reviewed by committee members specifically M/s BHEL/ L&T/ GE/
Toshiba and furnish their inputs to make it more broad based to cover other proven wet
limestone based technologies.
7. BHEL suggested that lime stone handling and slurry preparation be specified as different
facilities under scope of work. Further, the same concept should be adopted for gypsum
dewatering and handling/ storage.
8. NTPC raised concern about disposal of FGD effluent. CEA suggested that there are
many areas of low grade application in the plant such as ash handling and coal dust suppression
etc. where FGD waste water can be utilized/ disposed.
9. Toshiba/ GE suggested to design FGD plant based on design coal and guarantees shall
be based on flue gas parameters mentioned in the specification. CEA requested them to furnish
the suggested requirement of plant input conditions associated with design and guarantee
criteria mentioned in the specification.
10. Toshiba suggested to incorporate PM guarantees also at FGD outlet. The members were
of the opinion that FGD is being installed primarily for capturing SO2 only.
11. The issue of LD for shut down period for interconnection of FGD plant was discussed.
Toshiba/ GE/ BHEL were opined that there should not be any penalty clause on this aspect since
lot of issues crop up during execution and these are site specific. CEA opined that indefinite
leverage can not be extended on this account as the project will suffer huge generation loss and
LD for the same is must. Further, BHEL/L&T/GE/Toshiba requested to exclude consumption
of lime stone from guarantees under Cat. I. CEA clarified that since consumption of lime stone
has direct bearing on operating cost and hence required to be included for tender evaluation.
CEA apprised that auxiliary power consumption, limestone consumption and shut down period
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Annexures
have been included in Category- I guarantees, SO2 concentration in exit flue gas in Category-
II guarantees and SO2 removal efficiency has been included under category- III guarantees.
Indicative LD values have also been indicated in the draft specification. Committee members
were requested to review the same.
12. Members raised concerns that chimney lining may be an issue for FGD retrofit to be
done as per delivery schedule and integrating FGD with existing plant. Option of constructing
a new chimney needs to be explored to reduce the shut-down period from about 5-6 months
resulting in huge generation loss to 2-3 weeks required for integration only. Further, acid
resistant lining of existing chimney involves huge cost also. It was opined that construction of
new wet chimney of smaller height and its inter-connection with FGD system should be
included in the proposed specification of FGD plant.
13. Issue of SO2 guaranteed values to be indicated in specification so as the plant after
retrofit operates at below guaranteed values at part load was discussed. For MoEF&CC
notification requirement of 200 mg/Nm3, the specified value of 150 mg/Nm3 in the specification
was found to be in order.
14. Plant operation with FGD during start-up with oil firing was discussed in context with
damage to lining and GGH safety. NTPC clarified that rubber lining is not suitable and metallic
surfaces of absorber specified in their latest tenders can take care of this issue. CEA requested
NTPC to provide copy of their latest specification. NTPC agreed.
15. L&T/ NTPC proposed that guarantee values for HCl/ HF in flue gas and permissible
quantity of waste water from FGD should be indicated in the specification.
16. It was agreed that BHEL shall provide typical FGD scheme and layout drawings to be
incorporated in the specification.
17. NTPC shall provide the section on Quality Assurance Plan to be annexed with the
specification.
18. It was agreed that committee members shall furnish the information sought and also
their inputs on the draft specification to CEA through e- mail latest by 31st August, 2017.
******
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Standard Technical Specification for Retrofit of Wet Limestone Based Flue Gas Desulphurisation
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Annexures
List of Participants of 1st meeting of the Committee for Review of Draft technical specification for
FGD Plant held in CEA on 11.08.2017
435